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[0001] This application claims priority to Korean Patent Application No. 10-2011-0092525 filed on Sep. 14, 2011, and all the benefits accruing therefrom under 35 U.S.C. §119, the entire contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] (a) Field of the Invention
[0003] The invention relates to a vacuum roll-to-roll device and a manufacturing method of a roll-type substrate.
[0004] (b) Description of the Related Art
[0005] Attention to a flexible display device that is light and flexible and maintains device characteristics has been substantially increased together with rapid technique development of a display device. For a mass production of a low cost and high speed flexible display device, a continuous roll-to-roll process is necessary, rather than a batch type process that is based on a conventional glass substrate.
[0006] The roll-to-roll process is a process for executing formation of a thin film while unwinding/rewinding a polymer substrate made of a material such as polyethylene terephthalate (“PET”), polyethylene naphthalate (“PEN”), and polyethersulfone (“PES”) used to manufacture the flexible display device through an unwinding/rewinding roller, and has been largely researched as a high speed and mass production method for the flexible photoelectronic device of a next generation.
[0007] The process for forming the thin film may be generally executed in a high vacuum chamber. In the state that the roll-type substrate is placed inside the vacuum chamber, a shutter of the chamber is closed and air is withdrawn by a vacuum pump to form a vacuum. However, inflow of air is generated by minute cracks at an edge portion where the roll-type substrate and an O-ring of the shutter meet each other such that the vacuum degree inside the chamber is decreased.
BRIEF SUMMARY OF THE INVENTION
[0008] The invention provides a vacuum roll-to-roll device and a manufacturing method of a roll-type substrate to increase a vacuum degree of the vacuum roll-to-roll device.
[0009] A vacuum roll-to-roll device according to the invention includes: a first chamber; a second chamber neighboring the first chamber; a shutter disposed between the first chamber and the second chamber; and a sealing member attached to the shutter, and through which a roll-type substrate moves from the first chamber to the second chamber. A thickness of a lateral side of the roll-type substrate decreases in a direction toward an edge thereof.
[0010] The thickness of both of opposing lateral sides of the roll-type substrate decreases in a first direction, and the first direction may be substantially perpendicular to a direction in which the roll-type substrate moves from the first chamber to the second chamber.
[0011] The second chamber may form a large vacuum compared with the first chamber.
[0012] The sealing member may include a lower sealing member and an upper sealing member, and the shutter is closed when the lower sealing member and the upper sealing member contact each other and contact the roll-type substrate.
[0013] A portion of both of the opposing lateral sides of the roll-type substrate may contact the sealing member when the shutter is closed.
[0014] A separated space may be generated between the lower sealing member and the upper sealing member by a thickness of the roll-type substrate when the shutter is closed, and an edge portion of the roll-type substrate may fill the separated space.
[0015] The cross-sectional shape of the edge of the roll-type substrate may be a curved line.
[0016] The sealing member may be an O-ring of a rubber material.
[0017] A method of manufacturing a roll-type substrate according to the invention includes: unwinding a flexible substrate from an unwinding roller; cutting a lateral side of the flexible substrate by using a first cutter; and rewinding the flexible substrate of which the lateral side is cut through a rewinding roller. A knife portion of the first cutter is inclined at a portion which meets the flexible substrate.
[0018] The cutting of the lateral side of the flexible substrate may include cutting the lateral side of the flexible substrate by simultaneously using a second cutter which faces the first cutter with respect to the flexible substrate.
[0019] The knife portion of the first cutter and a knife portion of the second cutter may be disposed to meet the same position of the flexible substrate.
[0020] In the cutting of the lateral side of the flexible substrate, a thickness of a lateral side of the flexible substrate may decrease in a direction toward the edge thereof.
[0021] The thickness of both of opposing lateral sides of the flexible substrate may decrease in a first direction substantially perpendicular to an unwinding direction of the flexible substrate.
[0022] The first cutter includes two knife portions attached to a cylindrical body.
[0023] The two knife portions may be inclined at a portion which meets the flexible substrate.
[0024] The lateral side of the flexible substrate may be cut while rolling the cylindrical body of the first cutter in an opposite direction to an unwinding direction of the flexible substrate.
[0025] As above described, according to an exemplary embodiment of the invention, air which is inflowed to an inside the high vacuum chamber may be minimized by changing the design of one or both of opposing sides of the roll-type substrate.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] The above and other aspects and features of this disclosure will become more apparent by describing in further detail exemplary embodiments thereof with reference to the accompanying drawings, in which:
[0027] FIG. 1 is a cross-sectional view of an exemplary embodiment of a vacuum roll-to-roll device according to the invention.
[0028] FIG. 2 is a perspective view of the vacuum roll-to-roll device according to the invention.
[0029] FIG. 3 is a cross-sectional view of an exemplary embodiment of a shutter portion of a vacuum roll-to-roll device according to the invention.
[0030] FIG. 4 is a cross-sectional view of another exemplary embodiment of a shutter portion of a vacuum roll-to-roll device according to the invention.
[0031] FIG. 5 and FIG. 6 are cross-sectional views of an exemplary embodiment of a change of a vacuum degree of a vacuum roll-to-roll device according to the invention.
[0032] FIG. 7 is a graph of a change of the vacuum degree according to the exemplary embodiment of FIG. 5 and FIG. 6 .
[0033] FIG. 8 is a cross-sectional view of an air leakage space of a shutter portion of a conventional vacuum roll-to-roll device.
[0034] FIG. 9 is a cross-sectional view of an air leakage space of an exemplary embodiment of a shutter portion of a vacuum roll-to-roll device according to the invention.
[0035] FIG. 10 is a cross-sectional view of an air leakage space of another exemplary embodiment of a shutter portion of a vacuum roll-to-roll device according to the invention.
[0036] FIG. 11 is a perspective view of an exemplary embodiment of a manufacturing method of a roll-type substrate used for a vacuum roll-to-roll device according to the present invention.
[0037] FIG. 12 is an enlarged cross-sectional view of portion P of FIG. 11 .
[0038] FIG. 13 is a perspective view of another exemplary embodiment of a manufacturing method of a roll-type substrate used in a vacuum roll-to-roll device according to the invention.
[0039] FIG. 14 is a perspective view of another exemplary embodiment of a manufacturing method of a roll-type substrate used in a vacuum roll-to-roll device according to the invention.
[0040] FIG. 15 is a front view in a direction F of FIG. 14 .
[0041] FIG. 16 is a perspective view of another exemplary embodiment of a manufacturing method of a roll-type substrate used in a vacuum roll-to-roll device according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0042] Exemplary embodiments of the invention will be described in detail with reference to the accompanying drawings. However, the invention is not limited to exemplary embodiments described herein, and may be embodied in other forms. Rather, exemplary embodiments described herein are provided to thoroughly and completely understand the disclosed contents and to sufficiently transfer the ideas of the invention to a person of ordinary skill in the art.
[0043] In the drawings, the thickness of layers and regions is exaggerated for clarity. It is to be noted that when a layer is referred to as being “on” another layer or substrate, it can be directly formed on another layer or substrate or can be formed on another layer or substrate through a third layer interposed therebetween. In contrast, when an element is referred to as being “directly on” another element or layer, there are no intervening elements or layers present. Like constituent elements are denoted by like reference numerals throughout the specification. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.
[0044] It will be understood that, although the terms first, second, third, etc., may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms are only used to distinguish one element, component, region, layer or section from another region, layer or section. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the invention.
[0045] Spatially relative terms, such as “lower,” “under,” “above,” “upper” and the like, may be used herein for ease of description to describe the relationship of one element or feature to another element(s) or feature(s) as illustrated in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation, in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “lower” or “under” relative to other elements or features would then be oriented “above” relative to the other elements or features. Thus, the exemplary term “under” can encompass both an orientation of above and under. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.
[0046] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms “a,” “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.
[0047] Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.
[0048] All methods described herein can be performed in a suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”), is intended merely to better illustrate the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention as used herein.
[0049] Hereinafter, the invention will be described in detail with reference to the accompanying drawings.
[0050] FIG. 1 is a cross-sectional view of an exemplary embodiment of a vacuum roll-to-roll device according to the invention. FIG. 2 is a perspective view of the vacuum roll-to-roll device according to the invention. Referring to FIG. 1 and FIG. 2 , an exemplary embodiment of a vacuum roll-to-roll device according to the invention includes a first chamber and a second chamber. The first chamber and the second chamber face each other, and shutters 200 a and 200 b are disposed between the first chamber and the second chamber. The shutters 200 a and 200 b form boundaries of the first chamber and the second chamber and may be enclosed by a frame 250 . The second chamber may form a larger vacuum compared with the first chamber. The first chamber and the second chamber may be portions of one chamber that is spatially divided by the shutters.
[0051] The first chamber may be a load lock chamber which forms an environment for inserting a substrate into a process chamber before the substrate is inserted into the process chamber, and the second chamber may be a transfer chamber installed with a robot arm for transferring the substrate inside the first load lock chamber to the process chamber or transferring the substrate inside the process chamber to the first load lock chamber. However, the first chamber is not limited to the load lock chamber and the second chamber is not limited to the transfer chamber, and the second chamber may be applied to a case requiring a large vacuum.
[0052] A moving path is formed between the first chamber and the second chamber by an operation of opening and closing the shutters 200 a and 200 b. Sealing members 300 a and 300 b are attached to the shutters 200 a and 200 b, respectively. In the exemplary embodiment, the sealing members 300 a and 300 b may be O-rings, however they are not limited thereto. The O-rings 300 a and 300 b may include a rubber material.
[0053] In the vacuum roll-to-roll device according to the exemplary embodiment, the roll-type substrate 100 is unrolled by a driving roller 150 . The roll-type substrate 100 may be a flexible plastic substrate. The roll-type substrate 100 passes between the O-rings 300 a and 300 b according to a rotation of the driving roller 150 in a state that the shutters 200 a and 200 b are opened. Accordingly, the roll-type substrate 100 moves from the first chamber to the second chamber in a first direction d 1 .
[0054] FIG. 1 and FIG. 2 show a state that the shutters 200 a and 200 b are closed after a predetermined portion of the roll-type substrate 100 is moved into the second chamber in the first direction d 1 .
[0055] FIG. 3 is a cross-sectional view of an exemplary embodiment of a shutter portion of a vacuum roll-to-roll device according to the invention.
[0056] Referring to FIG. 3 , the lower O-ring 300 a is attached directly to the upper surface of the lower shutter 200 a, and the upper O-ring 300 b is attached directly to the lower surface of the upper shutter 200 b. FIG. 3 shows a state that the shutters 200 a and 200 b are closed.
[0057] The roll-type substrate 100 is interposed between the lower O-ring 300 a and the upper O-ring 300 b. The cross-section of a lateral side portion E of the roll-type substrate 100 according to the exemplary embodiment is tapered. While the shutters 200 a and 200 b are closed and the O-rings 300 a and 300 b are held against the roll-type substrate 100 , the shape of the O-rings 300 a and 300 b is changed or deformed by the thickness of the roll-type substrate 100 . A separated space H may be generated between the changed portion of the O-rings 300 a and/or 300 b and the edge of the roll-type substrate 100 . However, the cross-sectional surface of the lateral side portion E of the roll-type substrate 100 according to the exemplary embodiment is tapered such that the separated space H is minimized. In other word, the edge portion of the roll-type substrate 100 fills the separated space H.
[0058] In another exemplary embodiment, the cross-section of the lateral side portion E of the roll-type substrate 100 may be a curved line.
[0059] FIG. 4 is a cross-sectional view of another exemplary embodiment of a shutter portion of a vacuum roll-to-roll device according to the invention.
[0060] Most of the constitutions according to the exemplary embodiment shown in FIG. 4 are similar to the exemplary embodiment shown in FIG. 3 , and differences will be described. The description in FIG. 3 may be applied to the remaining constitutions except for the differences.
[0061] Referring to FIG. 4 , the cross-section of the lateral side portion E of the roll-type substrate 100 according to the exemplary embodiment has two tapers.
[0062] The lateral side portion E of the roll-type substrate 100 meets the lower O-ring 300 a and the upper O-ring 300 b. In the exemplary embodiment, the edge portion of the roll-type substrate 100 fills the larger space H compared with the exemplary embodiment descried in FIG. 3 .
[0063] In another exemplary embodiment, the cross-section of the edge lateral side portion E of the roll-type substrate 100 may be formed by engaging two curved lines.
[0064] FIG. 5 and FIG. 6 are cross-sectional views showing an exemplary embodiment of a change of a vacuum degree of a vacuum roll-to-roll device according to the invention. FIG. 6 is a cross-sectional view in the second direction A in the experimental example of FIG. 5 .
[0065] Referring to FIG. 5 and FIG. 6 , to verify how the vacuum degree is changed according to the magnitude of the separated space between the O-ring and the roll-type substrate edge, an aluminum foil 400 having a predetermined thickness is put on a chamber 500 , a cover 650 covers (e.g., overlaps) the chamber 500 , and an inlet is formed between the chamber 500 and the cover 650 . An O-ring 600 is disposed between the aluminum foil 400 and the wall of the chamber.
[0066] In the above configuration, a vacuum state is formed inside the chamber 500 by using a vacuum pump (not shown). The time to change the pressure inside the chamber to a vacuum state is then measured. This experiment is repeated while changing the thickness of the aluminum foil 400 , and the results thereof are shown in FIG. 7 .
[0067] FIG. 7 is a graph showing a change of the vacuum degree of the exemplary embodiment of FIG. 5 and FIG. 6 according to the invention. The time to change the pressure in seconds (Sec) is plotted against the change of pressure in torr (Torr).
[0068] Firstly, the vacuum degree is measured through Comparative Example 1 where the aluminum foil is not provided, an Exemplary Embodiment 1 where one sheet of the aluminum foil 400 having a thickness of 15 micrometers (um) is provided, an Exemplary Embodiment 2 where two sheets of the aluminum foil 400 having a thickness of 15 μm are provided, and an Exemplary Embodiment 3 where four sheets of the aluminum foil 400 having a thickness of 15 μm are provided.
[0069] Referring to FIG. 7 , as the number of aluminum foil sheets is increased, the time for forming the vacuum state is increased. That is, as the number of aluminum foil sheets is increased, a step formed in the O-ring is increased such that the separated space between the O-ring and the roll-type substrate edge is increased.
[0070] FIG. 8 is a cross-sectional view of an air leakage space of a shutter portion of a conventional vacuum roll-to-roll device.
[0071] Referring to FIG. 8 , the lateral side of the roll-type substrate 700 of the conventional vacuum roll-to-roll device has a surface that is substantially perpendicular to the upper surface of the substrate 700 . If the thickness of the roll-type substrate 700 is about 200 μm in a third direction, and is a plastic substrate, the area of the separated space H 1 may be calculated as follows. A maximum angle θ 1 is respectively between O-rings 800 a and 800 b, and a normal line to the substrate 700 . When the angle θ 1 of O-rings 800 a and 800 b is about 30 degrees in FIG. 8 , the area of the separated space H 1 is about 17,320 square micrometers (μm 2 ). A minimum angle θ 2 is respectively between O-rings 800 a and 800 b, and the normal line. When the angle θ 2 of the O-rings 800 a and 800 b is about 15 degrees, the area of the separated space H 1 is about 8,038 μm 2 . Accordingly, the area of the cross-section of the separated space H 1 respectively formed between the O-rings 800 a and 800 b and the edge portion of the roll-type substrate 700 , may be in the range of about 8,038 μm 2 to about 17,320 μm 2 .
[0072] FIG. 9 is a cross-sectional view of an exemplary embodiment of an air leakage space of a shutter portion of a vacuum roll-to-roll device according to the invention.
[0073] Referring to FIG. 9 , the cross-section of the exemplary embodiment of the roll-type substrate 100 of the vacuum roll-to-roll device according to the invention is tapered. If the thickness of the roll-type substrate 100 is about 200 μm in the third direction and is a plastic substrate, and the taper angle θ s is about 45 degrees, the area of the separated space H 2 may be calculated as follows.
[0074] A maximum angle θ 1 is between deformed O-ring 300 b and O-ring 300 a. If the angle θ 1 of the O-rings 300 a and 300 b is about 30 degrees in FIG. 9 , the area of the separated space H 2 may be calculated as follows.
[0075] The area of the separated space H 2 =½*200*400*sin(60 degrees)−½200*200=about 14,641 μm 2 .
[0076] A minimum angle θ 2 is between deformed O-ring 300 b and O-ring 300 a. If the angle θ 2 of the O-rings 300 a and 300 b is about 15 degrees in FIG. 9 , the area of the separated space H 2 may be calculated as follows.
[0077] The area of the separated space H 2 =14,641−½*400*200*tan(15 degrees)=about 3,923 μm 2 .
[0078] Accordingly, the area of the cross-section of the separated space H 2 formed between the O-rings 300 a and 300 b and the edge portion of the roll-type substrate 100 may be in the range of about 3,923 μm 2 to about 14,641 μm 2 .
[0079] FIG. 10 is a cross-sectional view of another exemplary embodiment of an air leakage space of a shutter portion of a vacuum roll-to-roll device according to the invention.
[0080] Referring to FIG. 10 , the exemplary embodiment of the cross-section of the roll-type substrate 100 of the vacuum roll-to-roll device according to the invention is double-tapered. If the thickness of the roll-type substrate 100 is about 200 μm in the third direction and is a plastic substrate, and the taper angle θ s is about 45 degrees, the area of the separated space H 3 may be calculated as follows.
[0081] A maximum angle θ 1 is respectively between O-rings 300 a and 300 b, and a normal line to the substrate 100 . If the angle θ 1 of the O-rings 300 a and 300 b is about 30 degrees in FIG. 10 , the area of the separated space H 3 may be calculated as follows.
[0082] The area of the separated space H 3 =½*200*200*sin(60 degrees)−1001*100=about 7,323.5 μm 2 .
[0083] A minimum angle θ 2 is respectively between O-rings 300 a and 300 b, and a normal line to the substrate 100 . If the angle θ 2 of the O-rings 300 a and 300 b is about 15 degrees in FIG. 10 , the area of the separated space H 3 may be calculated as follows.
[0084] The area of the separated space H 3 =7323.5−2*½200*100*tan(15 degrees)=about 1,961.5 μm 2 .
[0085] Accordingly, the area of the cross-section of the separated space H 3 respectively formed between the O-rings 800 a and 800 b and the edge portion of the roll-type substrate 100 may be in the range of about 1,961.5 μm 2 to about 7,323.5 μm 2 .
[0086] Referring to FIG. 8 to FIG. 10 , the area of the cross-section of the separated space is changed according to the design of the roll-type substrate, and it is possible to reduce the magnitude thereof.
[0087] In one exemplary embodiment, of the taper angle of the edge of the roll-type substrate and the physical property of the O-ring, an elastic coefficient tends to be proportional to a width of the separated space and tends to be inversely proportional to a force which closes the shutter. Accordingly, when the angle of the O-ring by the physical property of the O-ring and the force for closing the shutter is referred to as θ, and the taper angle of the roll-type substrate is referred to as θ s , if θ and θ s are ideally equal to each other, the area of the separated space in the third direction (e.g., thickness direction of the substrate) becomes 0 such that no air leakage will occur.
[0088] In other words, the taper angle of the roll-type substrate and the angle of the deformed O-ring are synchronized by controlling the physical property and the structure of the O-ring such that the magnitude of the separated space formed between the O-ring and the roll-type substrate is minimized. Accordingly, the air flowing into the high vacuum chamber may be minimized.
[0089] FIG. 11 is a perspective view of an exemplary embodiment of a manufacturing method of a roll-type substrate used in a vacuum roll-to-roll device according to the invention. FIG. 12 is an enlarged cross-sectional view of portion P of FIG. 11 .
[0090] Referring to FIG. 11 , an exemplary embodiment of a manufacturing method of a roll-type substrate according to the invention includes unwinding a flexible substrate 100 from an unwinding roller, cutting a lateral side of the substrate 100 in an opposite direction to a progressing direction (an arrow direction of FIG. 11 ) of the substrate 100 of by using a cutter K including a knife having an oblique line shape, and rewinding the roll-type substrate 100 of which the lateral side is cut through the rewinding roller.
[0091] Referring to FIG. 12 , the cutter K according to the exemplary embodiment is similar to a triangle knife used for engraving, and the knife portion 900 of the cutter K forms the angle θ s with respect to the upper surface of the substrate 100 . Accordingly, the lateral side of the roll-type substrate 100 cut by the cutter K is tapered with the angle θ s . The roll-type substrate 100 formed as described above forms the shape like the exemplary embodiment described in FIG. 3 .
[0092] FIG. 13 is a perspective view of another exemplary embodiment of a manufacturing method of a roll-type substrate used in a vacuum roll-to-roll device according to the invention.
[0093] Referring to FIG. 13 , an exemplary embodiment of the manufacturing method of the roll-type substrate in FIG. 13 is almost the same as the exemplary embodiment described in FIG. 11 and FIG. 12 . However, the lateral side of the substrate 100 is cut in the opposite direction to the progressing direction (the arrow direction of FIG. 12 ) of the substrate 100 by simultaneously using a plurality of cutters K above and under the substrate 100 . As described above, the roll-type substrate 100 forms the tapered lateral side portions having the shape like the exemplary embodiment described in FIG. 4 .
[0094] FIG. 14 is a perspective view of another exemplary embodiment of a manufacturing method of a roll-type substrate used in a vacuum roll-to-roll device according to the invention. FIG. 15 is a front view in a direction F of FIG. 14 .
[0095] Referring to FIG. 14 and FIG. 15 , most of the description of the exemplary embodiment described in FIG. 11 and FIG. 12 is applied to the exemplary embodiment, however the overall shape of the cutter K has differences. In the exemplary embodiment, the cutter K includes a cylindrical body and two knife portions attached to the cylindrical body. The knife portion forms the angle θ s with respect to the upper surface of the substrate 100 . Accordingly, the lateral side of the roll-type substrate 100 that is cut by the cutter K is tapered with the angle θ s . Also, the lateral side of the substrate 100 may be cut while rolling the cylindrical body in the opposite direction to the progressing direction (the arrow direction of FIG. 14 ) of the substrate 100 by using the cylindrical body of the cutter K.
[0096] Here, two knife portions are set to be inclined in different directions at the portions meeting the substrate 100 . In other words, two knife portions may be inclined to be substantially symmetrical to each other.
[0097] FIG. 16 is a perspective view of another exemplary embodiment of a manufacturing method of a roll-type substrate used in a vacuum roll-to-roll device according to the invention.
[0098] Referring to FIG. 16 , the manufacturing method of the roll-type substrate according to the exemplary embodiment is almost the same as the exemplary embodiment described in FIG. 14 and FIG. 15 . However, the lateral side of the substrate 100 is cut in the opposite direction to the progressing direction (the arrow direction of FIG. 16 ) of the substrate 100 by simultaneously using a plurality of cutters K above and under the substrate 100 .
[0099] While this invention has been described in connection with what is presently considered to be practical exemplary embodiments, it is to be understood that the invention is not limited to the disclosed embodiments, but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims. | A vacuum roll-to-roll device includes: a first chamber; a second chamber neighboring the first chamber; a shutter disposed between the first chamber and the second chamber; a sealing member attached to the shutter; and a roll-type substrate which moves from the first chamber to the second chamber through the sealing member. A thickness of a lateral side of the roll-type substrate decreases in a direction toward an edge thereof. | 3 |
This invention was made with Government support under Grant ROlCA43006 awarded by the National Institutes of Health. The Government has certain rights in the invention.
REFERENCE TO RELATED APPLICATION
This is a continuation in part of application Ser. No. 142,034, filed Jan. 11, 1988 now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the production and use of new porphyrin derivatives, to metal complexes of porphyrin derivatives, and to compositions containing the porphyrin derivatives and the metal complexes. More specifically, some of the porphyrin derivatives are compounds for which the name benzochlorins is suggested because they have a chlorin structure with an exocyclic benzene ring fused thereto, metal complexes of the benzochlorins, verdins, metal complexes of verdins, derivatives which form when certain purpurins stand in sunlight in contact with air, and metal complexes of the derivatives which form when the purpurins stand in sunlight in contact with air. All of these compounds are useful in the detection and treatment of tumors; after they have been administered systemically, e.g., intravenously, they localize preferentially in a tumor. After they have been administered, and have localized in a tumor, their presence can be detected by illumination with ultra violet light, which causes them to fluoresce. The porphyrin derivatives of the invention can also be used to treat tumors; after they have been administered and have localized, irradiation with light of a wave length at which they show an absorbance peak causes a reaction which has been found to involve the formation of singlet oxygen, and which damages or destroys the tumor where they have localized. The compositions containing the porphyrin derivatives and metal complexes thereof are solutions in an organic liquid that is physiologically acceptable for intravenous administration, emulsions thereof in saline solutions, or cyclodextrins in whose molecules the molecules of the porphyrin derivatives and metal complexes are encapsulated.
2. The Prior Art
Certain porphyrins and families of purpurins and chlorins and metal complexes thereof and the use of the purpurins, chlorins, metal complexes and porphyrins in the manner described above for the detection and treatment of tumors are all known. For example, PCT/US86/02824 discloses certain purpurins, chlorins, and metal complexes thereof, and their use for the detection and treatment of tumors In addition, European patent application EP142,732 is said (C.A. 103: 123271S) to disclose certain chlorins of a different family and that they accumulate preferentially in the cancer cells of hamsters infected with pancreatic cancer.
Further, a chemical mixture derived from hematoporphyrin, called hematoporphyrin derivative, and often abbreviated "HpD", can be administered intravenously and used in the manner described above for the detection and treatment of tumors. Hematoporphyrin can be produced from protoporphyrin IX, a porphyrin that can be separated from blood. HpD is a mixture of many different porphyrins and related compounds, the exact composition not being fully known (see, for example, Porphyrin Photosensitization, edited by David Kassel and Thomas J. Dougherty, Plenum Press, New York and London, 1983, pp. 3-13). As a consequence, the chlorins and purpurins of PCT/US86/02824 are preferred over HpD for this use because they are single, known compounds. In addition, the chlorins and purpurins have absorbance peaks at longer wavelengths and show greater absorbances, by comparison with HpD; the longer wavelength peaks are advantageous because light of the longer wavelengths is capable of greater penetration of tissue, while the greater absorbances are desirable because less light energy is required to cause a given degree of reaction.
The production of the nickel complex of an octa-ethyl benzochlorin has been disclosed (Arnold et al., J.C.S. PERKIN I, pages 1660-1670, 1979). The complex is produced by reaction in dry NN-dimethylformamide between phosphorus oxychloride and nickel meso-vinyl octaethylporphyrin. The major product reported was nickel 5-(β-Formylvinyl) octaethylporphyrin (80 percent yield); in addition, the authors reported a 5 percent yield of the nickel benzochlorin and a 15 percent yield of a demetallated product (which was not a benzochlorin) The nickel octaethylbenzochlorin has been found to be substantially inert insofar as the ability to cause a cytotoxic response is concerned.
The production of a verdin isomer mixture by refluxing a mesorhodin isomer mixture in acetic acid has been reported (The Porphyrins, Volume II, pages 137 and 138, edited by David Dolphin, Academic Press, New York, San Francisco and London, 1978. Woodward et al. J.A.C.S., 1960, 82, p. 3800 and Morgan, J.Org.Chem., 1986, 51, 1347 disclose that the porphyrin derivatives form when purpurins stand in sunlight in the presence of air.
The benzochlorins, the verdins, the derivatives which form when purpurins stand in sunlight in contact with air and metal complexes of the instant invention have the same advantages as the purpurins, chlorins and metal complexes, and, in some cases, the significant additional advantage that substantially smaller doses are required to cause a given cytotoxic response.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a structural formula for metal complexes of the family of benzochlorins according to the invention.
FIG. 2 is a structural formula for metal complexes of a family of verdins according to the invention.
FIG. 3 is a structural formula for the family of benzochlorins according to the invention.
FIG. 4 is a structural formula for verdins of the family of FIG. 2.
FIG. 5 is a structural formula for metal complexes of a family of verdins which may be isomers of the complexes of FIG. 2.
FIG. 6 is a structural formula for verdins of the family of FIG. 5.
FIG. 7 is a structural formula for a family of porphyrins which can be used to produce verdins and metal complexes thereof according to the invention.
FIG. 8 is a structural formula for metal complexes of porphyrins which can be used to produce benzochlorins and metal complexes thereof according to the invention.
FIG. 9 is a structural formula for a family of porphyrin derivatives which form when the corresponding purpurins stand in sunlight in the presence of air.
FIG. 10 is a structural formula for metal complexes of the porphyrin derivatives of FIG. 9.
BRIEF DESCRIPTION OF THE INVENTION
The instant invention, in one aspect, is a metal complex of a benzochlorin, of a verdin, or of a porphyrin derivative having the structure of FIG. 1, of FIG. 2, of FIG. 5 or of FIG. 10 or is a benzochlorin having the structure of FIG. 3 of the attached drawings, where M is a metal, for example, Ag, Al, Ce, Co, Cr, Cu, Dy, Er, Eu, Fe, Ga, Gd, Hf, Ho, In, La, Lu, Mn, Mo, Nd, Pb, Pd, Pr, Pt, Rh, Sb, Sc, Sm, Sn, Tb, Th, Ti, Tl, Tm, U, V, Y, Yb, Zn or Zr,
R13 is an alkyl group having from 1 to 4 carbons, and
each of R1 through R12 and R14 is:
H or CHO,
a primary or secondary alkyl group having from 1 to 4 carbon atoms,
an alkylene group having from 2 to 4 carbon atoms,
a group having the formula R 2 N(R 3 ) 2 where R 2 is a bivalent aliphatic hydrocarbon radical having from 1 to 4 carbon atoms, wherein any carbon to carbon bond is either a single or a double bond, and not more than one is a double bond; R 3 is hydrogen or an alkyl radical having from 1 to 2 carbon atoms and the two R 3 groups can be the same or different,
a group having the formula R 2 N(R 4 ) 3 + where R 2 is a bivalent aliphatic hydrocarbon radical having from 1 to 4 carbon atoms, wherein any carbon to carbon bond is either a single or a double bond, and not more than one is a double bond; and R 4 is an alkyl group having from 1 to 2 carbon atoms and the three R 4 groups can be the same or different,
a group having the formula R 2 OH were R 2 is a bivalent aliphatic hydrocarbon radical having from 1 to 4 carbon atoms, wherein any carbon to carbon bond is either a single or a double bond, and not more than one is a double bond, or
CO 2 R', CH 2 CO 2 R' or CH 2 CH 2 CO 2 R' where R' is H, or a primary or secondary alkyl group having from one to four carbon atoms, with the proviso that R14 can be SO 3 H or a physiologically acceptable salt thereof.
In another aspect, the invention is a solution in an organic liquid which is physiologically acceptable for intravenous or topical administration of one of the foregoing benzochlorins, verdins, porphyrin derivatives or metal complexes, or an aqueous emulsion of such a solution.
In still another aspect, the invention is a structure in which the molecules of one of the foregoing benzochlorins, verdins, porphyrin derivatives or metal complexes are encapsulated in the molecules of a cyclodextrin.
In yet another aspect, the invention is a method for detecting and treating tumors which comprises administering an effective amount of one of the foregoing benzochlorins, a metal complex of one of the foregoing benzochlorins, one of the foregoing verdins, a metal complex of one of the foregoing verdins, one of the foregoing porphyrin derivatives, or a metal complex of one of the foregoing porphyrin derivatives to a human or animal patient, and irradiating the relevant region of the patient with ultra violet or visible light of a wavelength at which the benzochlorin, benzochlorin metal complex, verdin, verdin metal complex, porphyrin derivative or porphyrin derivative metal complex has an absorbance peak.
OBJECTS OF THE INVENTION
It is, therefore, an object of the invention to provide a new composition which is a benzochlorin having the structure of FIG. 3 of the attached drawings, a metal complex of a benzochlorin having the structure of FIG. 1 of the attached drawings, a metal complex of a verdin having the structure of FIG. 2 or of FIG. 5 of the attached drawings, or a metal complex of a porphyrin derivative having the structure of FIG. 10 of the attached drawings.
It is another object of the invention to provide a solution in an organic liquid of a benzochlorin having the structure of FIG. 3 of the attached drawings, a metal complex of a benzochlorin having the structure of FIG. 1 of the attached drawings, a verdin having the structure of FIG. 4 or FIG. 6 of the attached drawings, a metal complex of a verdin having the structure of FIG. 2 or FIG. 5 of the attached drawings, a porphyrin derivative having the structure of FIG. 9 of the attached drawings, or a metal complex of a porphyrin derivative having the structure of FIG. 10 of the attached drawings.
It is a further object to provide an aqueous emulsion of a solution in an organic liquid of a benzochlorin having the structure of FIG. 3 of the attached drawings, a metal complex of a benzochlorin having the structure of FIG. 1 of the attached drawings, a verdin having the structure of FIG. 4 or FIG. 6 of the attached drawings, a metal complex of a verdin having the structure of FIG. 2 or FIG. 5 of the attached drawings, a porphyrin derivative having the structure of FIG. 9 of the attached drawings, or a metal complex of a porphyrin derivative having the structure of FIG. 10 of the attached drawings.
It is still another object of the invention to provide a composition in which molecules of a benzochlorin having the structure of FIG. 3 of the attached drawings, a metal complex of a benzochlorin having the structure of FIG. 1 of the attached drawings, a verdin having the structure of FIG. 4 or of FIG. 6 of the attached drawings, a metal complex of a verdin having the structure of FIG. 2 or of FIG. 5 of the attached drawings, a porphyrin derivative having the structure of FIG. 9 of the attached drawings, or a metal complex of a porphyrin derivative having the structure of FIG. 10 of the attached drawings are encapsulated in the molecules of a cyclodextrin.
It is yet another object of the invention to provide a method for detecting and treating tumors which comprises administering one of the foregoing benzochlorins, benzochlorin metal complexes, verdins, verdin metal complexes, porphyrin derivatives or porphyrin derivative metal complexes to a human or animal patient.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Examples 1 through 9 hereof set forth the best mode presently contemplated by the inventors, insofar as this invention is directed to benzochlorins, benzochlorin metal complexes, verdins, verdin metal complexes, porphyrin derivatives and porphyrin derivative metal complexes and their production. The in vivo test procedures describe the best mode insofar as this invention is directed to solutions of the benzochlorins, benzochlorin metal complexes, verdins, verdin metal complexes, porphyrin derivatives and porphyrin derivative metal complexes in an organic liquid and to the production of such solutions, and the in vivo test procedures describe the best mode insofar as the invention is directed to the use of benzochlorins, benzochlorin metal complexes, verdins, verdin metal complexes, porphyrin derivatives and porphyrin derivative metal complexes for the detection and treatment of tumors.
In the examples, and elsewhere herein, the term "percent v / v " means percent by volume; the term "percent w / w " means percent by weight; the term "alkyl group" is used in its ordinary sense to mean a monovalent, saturated, aliphatic hydrocarbon radical; the term "alkylene group" is used in its ordinary sense to mean a monovalent, aliphatic hydrocarbon radical which has one carbon to carbon double bond and in which any other carbon to carbon bond is a single bond; all temperatures are in °C.; and the following abbreviations have the meanings indicated: mg=milligram or milligrams; g=gram or grams; kg=kilogram or kilograms; ml=milliliter or milliliters; cm=centimeter or centimeters; ε=molar absorptivity; mw=milliwatts; and nm=nanometer or nanometers.
EXAMPLE 1
The production of a novel benzochlorin according to the invention (hereafter "octaethyl benzochlorin") from nickel meso-formyl octaethyl porphyrin is described in this example. The production of nickel meso-formyl octaethyl porphyrin is described in a journal article by R. Grigg et al., J. Chem. Soc. Perkin Trans I, 1972, pp. 1789,1798; it has the formula of FIG. 8 of the attached drawings where R1 through R8 are ethyl, R10 through R12 are hydrogen, R is CHO, and M is Ni. Four intermediates were produced in the Example 1 procedure, nickel meso-(β-ethoxycarbonylvinyl)- octaethyl porphyrin, which has the formula of FIG. 8 of the attached drawings where R1 through R8 are ethyl, R10 through R12 are hydrogen, R is CH═CHCO 2 CH 2 CH 3 , and M is Ni, nickel meso(β-hydroxymethyl- vinyl) octaethyl porphyrin, which has the formula of FIG. 8 of the attached drawings where R1 through R8 are ethyl, R10 through R12 are hydrogen, R is CH═CHCH 2 OH, and M is nickel, nickel meso-(β-formylvinyl)octaethyl porphyrin, which has the formula of FIG. 8 of the attached drawings where R1 through R8 are ethyl, R10 through R12 are hydrogen, R is CH═CHCHO, and M is nickel, and nickel octaethyl benzochlorin, which has the formula of FIG. 1 of the attached drawings where R1 through R8 are ethyl, R10 through R12 are hydrogen, and M is nickel. Octaethyl benzochlorin has the formula of FIG. 3 of the attached drawings where R1 through R8 are ethyl, and R10 through R12 are hydrogen.
Production of nickel meso-(β-ethoxycarbonylvinyl)octaethyl porphyrin
A solution of 506 mg nickel meso-formyl octaethyl porphyrin and 1.024 g (carbethoxymethylene)triphenyl- phosphorane in 50 ml xylene was heated under reflux for 18 hours. The solution was cooled; the xylene was removed in vacuo; and the solid which remained was dissolved in the minimum amount of dichloromethane and chromatographed on silica. A minor fraction of nickel octaethyl porphyrin and a major red fraction were recovered. The solvent was removed from the red fraction; the solid which remained was recrystallized from a solvent composed of equal parts by volume of dichloromethane and methanol, yielding 455 mg small brown needles. The product was identified by nuclear magnetic resonance as nickel meso-(β-ethoxycarbonylvinyl) octaethyl porphyrin; it showed visible spectrum absorbance peaks at 405, 530 and 565 nanometers (94 180, 18 604, 27 790).
Production of nickel meso-(β-hydroxymethylvinyl)octaethyl porphyrin
Two solutions were prepared, a first by dissolving 50 mg nickel meso-(β-ethoxycarbonylvinyl)octaethyl porphyrin in 50 ml dry diethyl ether under nitrogen and a second by dissolving 5 mg lithium aluminum hydride in 10 ml diethyl ether. The first solution was kept under nitrogen while the second was added quickly thereto at room temperature of about 22°, and the solution which resulted was allowed to stand for 24 hours under nitrogen. The reaction was then quenched by making incremental additions of 15 percent w / w aqueous ammonium chloride until an addition did not cause effervescence. The organic layer was then collected and washed with three 50 ml portions of water. The solvent was then evaporated, and the solid residue was chromatographed on silica gel, using dichloromethane as the solvent. The major red band was collected. Red crystals of the desired product were recovered by evaporating the solvent and were crystallized from dichloromethane containing 2 percent v / v methanol. The yield was 26 percent of theory, U V lambda maximum 559 nm.
Production of Nickel meso-(β-formylvinyl)octaethyl porphyrin
A solution was prepared by dissolving 100 mg nickel meso-(β-hydroxymethylvinyl)octaethyl porphyrin and 108 mg pyridine dichromate in 100 ml dichloromethane, and was allowed to stand under a nitrogen atmosphere for about 16 hours. The dichloromethane was then evaporated and the reaction products were dissolved in diethyl ether, leaving a residue of insoluble chromium salts, which were separated by filtration. The organic layer was collected. The diethyl ether was removed by evaporation and the product was chromatographed on a silica gel column, using dichloromethane as the eluent. The major reddish green fraction was collected; the solvent was removed by evaporation and the residue was crystallized from dichloromethane containing 2 percent v / v methanol. The crystallized product was identical, spectroscopically, to that reported in the literature (Arnold et al., J.C.S. PERKIN I, pages 1660-1670, 1979).
Production of Ni Octaethyl benzochlorin
A 200 mg portion of Ni meso-(β-formylvinyl) octaethyl porphyrin was treated with 4 ml concentrated (98 percent w / w ) sulfuric acid for two hours. The reaction product was then poured into 20 ml water, neutralized with sodium hydrogen carbonate, and extracted with dichloromethane. The organic layer was collected and washed with water, and the dichloromethane was removed by evaporation. The residue was chromatographed on silica gel, using dichloromethane as the solvent. The major green band was collected, and the solvent was removed by evaporation. The residue was crystallized from dichloromethane containing 2 percent v / v methanol. The crystallized product (yield, 40 percent) was identical, spectroscopically, to that reported in the literature (Arnold et al., J.C.S. PERKIN I, pages 1660-1670, 1979).
Production of Octaethyl benzochlorin
A 40 mg portion of nickel octaethyl benzochlorin was stirred for 21/4 hours in 4 ml concentrated (98 percent w / w ) sulfuric acid. The reaction mixture which resulted was poured onto ice, neutralized with sodium hydrogen carbonate, and extracted with dichloromethane. Two reaction products (20 mg of each) were recovered by chromatographing the extract on silica gel. One of the products was identified as octaethyl benzochlorin, while the other was identified as the sulfonate thereof. The sulfonate was found to have the structure of FIG. 3 of the drawings, where R13 is SO 3 Na, and is attached either to the available carbon nearer R2 or to the available carbon nearer R3, probably the former. The octaethyl benzochlorin was crystallized from dichloromethane containing 2 percent v / v methanol, while the octaethyl benzochlorin sulfonate was crystallized from dichloromethane. Lambda maximum, U V, was 657 nm for both products. The SO 3 Na group can be converted to SO 3 H by acidifying the sulfonate, and the hydrogen of the SO 3 H group can be converted to other cations by neutralizing with other bases.
EXAMPLE 2
Production of Zn Octaethyl Benzochlorin
A solution was prepared by dissolving 20 mg octaethyl benzochlorin in a mixed solvent composed of 15 ml dichloromethane and 5 ml methanol and 100 mg zinc acetate was added to the solution; the mixture which resulted was refluxed for about 24 hours until the electronic spectrum of the reaction mixture indicated that chelation was complete. The reaction mixture was then concentrated to 7 ml and allowed to cool to room temperature of about 22°. Product which precipitated was recovered by filtration, dissolved in a mixed solvent composed of 5 ml dichloromethane and 2 ml methanol, and recrystallized, yielding 18 mg Zn octaethyl benzochlorin in the form of microcrystals. The Zn octaethyl benzochlorin, a metal complex, has the formula of FIG. 1 of the attached drawings where R1 through R8 are ethyl, R10 through R12 are hydrogen and M is Zn; the compound has a visible spectrum absorbance peak at 850 nanometers.
EXAMPLE 3
The production of "Verdin I" from coproporphyrin I, tetramethyl ester, is described in this Example. The coproporphyrin I, tetramethyl ester, starting material had the structure of FIG. 7 of the attached drawings where R and R10 through R12 are hydrogen, R1, R3, R5, and R7 are CH 3 and R2, R4, R6 and R8 are CH 2 CH 2 CO 2 CH 3 . "Verdin I" has the structure of FIG. 6 of the attached drawings where R10 through R12 are hydrogen, R1, R3, R5, and R7 are CH 3 and R4, R6, and R8 are CH 2 CH 2 COOCH 3 .
Production of Verdin I
A 100 mg portion of coproporphyrin I, tetramethyl ester was heated to 80° with 2 ml concentrated (98 percent w / w ) sulfuric acid for about 5 hours until an absorbance peak developed in the visible spectrum at 695 nm. The reaction product was then cooled and stirred for 16 hours in 100 ml methanol. Solvent was then removed from the solution by evaporation until its volume was 20 ml, and the concentrated solution was poured into an equal volume of water. Organic material was then extracted into dichloromethane and solvent was removed from the extract by evaporation. The solid residue was chromatographed on silica gel, using dichloromethane containing 2 percent v/v of methanol as the eluent. A major green band was collected, and the Verdin I was recovered by evaporating the solvent. It was found to have an absorbance peak in the visible spectrum at 695 nm. The Verdin I zinc complex was prepared by the method described in Example 2; it was found to have a very broad absorbance peak in the visible spectrum spanning 680 to 725 nm.
EXAMPLE 4
The procedure described in Example 1 has been used to produce other benzochlorins. A typical one of the starting materials, Nickel meso-formyletio porphyrin I, produced four intermediates [I] Nickel meso-(β-ethoxycarbonylvinyl)-etio porphyrin I, [II] Nickel meso-(β-hydroxymethylvinyl)- etio porphyrin I, [III] Nickel meso-(β-formylvinyl)-etio porphyrin I and [IV] Nickel etiobenzochlorin. Both etiobenzochlorin and its sodium sulfonate (structure of FIG. 3 where R14 is SO 3 Na) were produced. The starting material and all of the first three intermediates have the structure of FIG. 8 of the attached drawings where R1, R3, R5, and R7 are CH 3 , R2, R4, R6 and R8 are CH 2 CH 3 , R10 through R12 are hydrogen, and M is nickel. R is CHO in the starting material, CH═CHCO 2 CH 2 CH 3 in the first intermediate, CH═CHCH 2 OH in the second intermediate, and CH═CHCHO in the third intermediate. The fourth intermediate was a mixture of two isomers, one having the structure of FIG. 1, and one having a similar structure, except that it was the pyrrole ring to which R3 and R4 were attached that was reduced, and to which the benzene ring was fused. The etiobenzo chlorin was also a mixture of two isomers, one having the structure of FIG. 3, and one having a similar structure, except that it was the pyrrole ring to which R3 and R4 were attached that was reduced, and to which the benzene ring was fused.
The procedure of Example 3 has been used to produce other verdins. Typical ones of the starting materials and of the verdins produced are set forth in Examples 5 through 7.
EXAMPLE 5
______________________________________Compound Formula of______________________________________Starting Material, Deuteroporphyrin IX FIG. 7*Final product, an isomeric mixture of Verdin II FIG. 4*and Verdin III FIG. 6______________________________________ *where: R1, R4, R6 and R8 are CH.sub.3, and R5, R7 and R10 through R12 are hydrogen; In the starting material, R is hydrogen and R2 and R3 are CH.sub.2 CH.sub.2 COOCH.sub.3 ; In Verdin II, R2 is CH.sub.2 CH.sub.2 COOCH.sub.3 ; In Verdin III, R3 is CH.sub.2 CH.sub.2 COOCH.sub.3.
EXAMPLE 6
______________________________________Compound Formula of______________________________________Starting Material, Meso-porphyrin IX FIG. 7*Final product an isomeric mixture of Verdin IV FIG. 4*and Verdin V FIG. 6*______________________________________ *Where: R1, R4, R6 and R8 are CH.sub.3, R5 and R7 are CH.sub.2 CH.sub.3, and R10 through R12 are hydrogen. In the starting material, R is hydrogen and R2 and R3 are CH.sub.2 CH.sub.2 COOCH.sub.3. In Verdin IV, R2 is CH.sub.2 CH.sub.2 COOCH.sub.3. In Verdin V, R3 is CH.sub.2 CH.sub.2 COOCH.sub.3.
EXAMPLE 7
______________________________________Compound Formula of______________________________________Starting Material, Methyl pyrroporphyrin FIG. 7*Final product, Verdin VI FIG. 6*______________________________________ *Where: R1, R3, R6 R7 and R8 are CH.sub.3, R4 and R5 are CH.sub.2 CH.sub.3 and R1 through R12 are hydrogen. In the starting material, R2 is CH.sub.2 CH.sub.2 COOCH.sub.3 and R is hydrogen.
The procedure was modified, by comparison with that of Example 3, in that, after the visible spectrum peak developed at 695 nm, the steps of pouring the reaction product into 100 ml methanol and stirring for 16 hours were omitted. The purpose of these steps, in Example 3, was to re-esterify any free COOH groups; they were unnecessary in Example 7, because neither the starting porphyrin nor Verdin VI includes a moiety that would form free COOH groups.
The production of a porphyrin derivative having the structure of FIG. 9 of the attached drawings from the corresponding purpurin is described in the following example.
EXAMPLE 8
A 50 mg portion of Purpurin NT2 was dissolved in 20 ml dichloromethane, and the resulting solution was allowed to stand for a total of 16 hours in sunlight, in contact with air, and under ambient conditions (temperature about 22°). The dichloromethane was then removed by evaporation, leaving 50 mg porphyrin derivative (hereafter "Porphyrin NT2") which was found by nuclear magnetic resonance to have the formula of FIG. 9 of the attached drawings where R1 through R8 are ethyl, R10 through R12 are hydrogen, and R13 is CH 2 CH 3 . The production of Purpurin NT2 is described in Example 1 of PCT/US86/02824; it has the formula of FIG. 5 of the drawings of that application where R1 through R8 are ethyl, R9 is CO 2 CH 2 CH 3 , and R10 through R13 are hydrogen.
The production of a porphyrin derivative metal complex having the structure of FIG. 10 of the attached drawings from the corresponding purpurin metal complex is described in the following example.
EXAMPLE 9
A 50 mg portion of Zn Purpurin NT2 was dissolved in 20 ml dichloromethane, and the resulting solution was allowed to stand for a total of 16 hours in sunlight, in contact with air, and under ambient conditions (temperature about 22°). The dichloromethane was then removed by evaporation, leaving 50 mg porphyrin derivative, zinc complex (hereafter "Zn Porphyrin NT2") which was found by nuclear magnetic resonance to have the formula of FIG. 10 of the attached drawings where R1 through R8 are ethyl, R10 through R12 are hydrogen, and R13 is CH 2 CH 3 . The production of Zn Purpurin NT2 is described in Example 2 of PCT/US86/02824; it has the formula of FIG. 1 of the drawings of that application where R1 through R8 are ethyl, R9 is CO 2 CH 2 CH 3 , R10 through R13 are hydrogen, and M is Zn.
The procedures of Examples 8 and 9 have been used to produce other porphyrin derivatives and metal complexes from purpurins and purpurin metal complexes disclosed in PCT/US86/02824 Examples of the porphyrin derivatives and metal complexes are given in the following table, where names are assigned to the porphyrin derivatives and metal complexes. In all cases, names used in the table for the purpurins and purpurin metal complexes have the meanings set forth therefor in the PCT application, and the structural differences between the porphyrin derivatives and metal complexes and the purpurins and purpurin metal complexes from which they are produced are analogous to those between Porphyrin NT2 and Purpurin NT2.
______________________________________ Porphyrin derivative orPurpurin or Metal Complex Metal Complex______________________________________Sn(IV) Purpurin NT2 Sn(IV) Porphyrin NT2Purpurin ET2 Porphyrin ET2Zn Purpurin ET2 Zn Porphyrin ET2Sn(IV) Purpurin ET2 Sn(IV) Porphyrin ET2______________________________________
In vivo testing of various compounds according to the invention was conducted on male Fisher 344 rats weighing 135 to 150 g in whom the transplantable FANFT (N-[4-(5-nitro2-furyl)-2-thiazolyl]formamide tumor system had been implanted. (Use of this system is reported by Selman, S. H., et al., Cancer Research, pp. 1924-1927, May, 1984.) Two tumors were implanted into the subcutaneous tissue of the flanks of each test animal; when the testing was carried out, each tumor was about 1 cm in diameter.
In some instances, the compounds tested were dissolved in a commercially available non-ionic solubilizer and emulsifier obtained by reacting ethylene oxide with castor oil in a ratio of 35 moles of ethylene oxide per mole of castor oil, diluting the resulting solution with 1,2-propanediol, and producing an emulsion with the resulting solution and 0.9 percent w/w aqueous sodium chloride solution. The specific non-ionic solubilizer used is available from BASF under the designation CREMOPHOR EL; it is composed of fatty acid esters of polyglycols, glycerol polyglycols, polyethylene glycols and ethoxylated glycerol. The test solutions were prepared from 5 mg test compound, 0.5 ml warm solubilizer (enough to dissolve the test compound), enough 1,2-propanediol to make a solution of the test compound in a mixed diol/solubilizer solvent containing 32.9 percent w/w solubilizer; finally, enough 0.9 percent w/w aqueous sodium chloride was added to make 2 ml test solution so that the final concentration of the test compound in the test solution was 2.5 mg per ml. Each test solution was made, with mechanical shaking and stirring, by dissolving the test compound in the solubilizer, diluting the resulting solution with the indicated amount of 1,2-propanediol, and adding the sodium chloride solution to the diluted solution. A control solution was also prepared for use with each test solution. The control was identical with the test solution except that it contained no test compound. The test solutions were prepared in air, but it is believed that a nitrogen atmosphere would be advantageous because it would minimize the chance of a reaction with oxygen.
In other cases a solution made by dissolving 5.2 μmole of the compound under test in 1 ml chloroform was mixed with a 0.1M phosphate buffer containing 150 μmole sodium chloride and 20.8 μmole τ-cyclodextrin, and the resulting composition was vortexed under pressure until the chloroform had evaporated completely, at which time it was found that an aqueous solution of an inclusion complex had been produced in which the molecules the compound under test were encapsulated within molecules of the cyclodextrin.
Molecules of phthalocyanines, for example, zinc phthalocyanine, can also be encapsulated within cyclodextrin molecules by the method described in the preceding paragraph, but a different solvent, e.g., tetrahydrofuran, should be substituted for the chloroform. Such compositions are significantly advantageous by comparison with previously known delivery systems for phthalocyanines.
Three cyclodextrins are known, α, β and τ. The molecules of all three are annular rings 0.78 nm high. The outer and inner diameters are, for β-cyclodextrin, 1.37 and 0.57 nm, for β-cyclodextrin, 1.53 and 0.78 nm, and, for τ-cyclodextrin, 1.69 35 and 9.5 nm.
The testing involved injecting each rat with a solution of the compound under test, dosage 1 mg test compound per kg of body weight or with the same volume of the appropriate control, irradiating one of the two tumors with light for 30 minutes, sacrificing the animals, and examining the tumors. The injections were made via the dorsal tail vein. The irradiation of one of the tumors occurred twenty four hours after each rat was injected while the other of the two tumors was shielded by an opaque box.
Tumor temperature and body core temperature were monitored, using thermistors, one placed into the tumor and one placed intrarectally. Tumor temperature was kept within 2° of body core temperature by directing a jet of cool air over the tumor.
The light source was a slide projector that had a 500 watt bulb fitted with a red filter which is available from Corning Glass Works under the designation 2418. The light was reflected 90° by a silvered mirror, and was focused onto the tumor with a secondary condensing lens. The light intensity on the tumor was monitored, using a photometer /radiometer that is available from United Detector Technology under the designation "UDT #351", and was maintained at 200 mw per cm 2 .
Six rats were injected with each test solution and two were injected with the appropriate control solution
Four hours after the irradiation, three of the rats that had been injected with the test solution and one of the rats that had been injected with the control were sacrificed by an intracardiac injection of saturated aqueous potassium chloride solution. Twenty four hours after the irradiation, another three of the rats that had been injected with the test solution and the other rat that had been injected with the control were sacrificed in the same way. During the testing, the rats were under barbituate anesthesia (65 mg per kg body weight).
The tumors were then excised, placed in 10 percent w/w phosphate-buffered formalin and cut into three sections perpendicular to their long axis. The tumors were then embedded in paraffin and cut into sections five microns in width. The sections were stained with hematoxylin and eosin.
Histologic examination of the stained sections revealed that all purpurins, benzochlorins, porphyrin derivatives (FIG. 9 of the attached drawings) and verdins tested, and their metal complexes, with the exception of the nickel complexes, produced hemorrhage, vacuolization, vascular stasis and necrosis. The purpurins and benzochlorins were the most active compounds, followed by the porphyrin derivatives (FIG. 9) and the verdins. This test did not show a difference between emulsions of the compounds and cyclodextrin solutions in which molecules of the compounds were encapsulated within molecules of the cyclodextrin.
The production of Octaethyl benzochlorin, Zn octaethyl benzochlorin, Verdin I, Verdin I zinc complex, Etiobenzochlorin, an isomeric mixture of Verdin II and Verdin III, an isomeric mixture of Verdin IV and Verdin V, Verdin VI, Porphyrin NT2, and Zn Porphyrin NT2 is described in the foregoing Examples hereof. In each case, the benzochlorin had the structure of FIG. 3 of the attached drawings and the verdin the structure of FIG. 4 where R1 through R8 had certain meanings and R10 through R12 were hydrogen. The benzochlorins were produced from metal complexes of porphyrins having the structure of FIG. 8 of the attached drawings where R1 through R8 meant the same as in the benzochlorins, R was CHO, and R10 through R12 were hydrogen. The verdins were produced from porphyrins having the structure of FIG. 7 of the attached drawings where one of R2, R3, R6 and R7 had the structure CH 2 CH 2 COOR', where R' is an alkyl group, preferably methyl, and the others of R1 through R8 had the same meanings as in the verdins.
The other metal porphyrins which are required for substitution in the procedure of Example 1 for nickel meso-formyl octaethyl porphyrin to produce the benzochlorins having the structure of FIG. 3 of the drawings where R10 through R12 are hydrogen are either disclosed in the literature or can be produced by methods that are disclosed in the literature. Similarly, the other porphyrins which are required for substitution in the procedure of Example 3 for coproporphyrin I, tetramethyl ester to produce the verdins having the structure of FIG. 4 of the drawings where R10 through R12 are hydrogen are either disclosed in the literature or can be produced by methods that are disclosed in the literature.
In general, porphyrins are produced by condensing two pyrroles, and by then condensing two of the condensation products. The two condensation products can be the same or different, and each can be made by condensing two pyrroles that are the same or different. The pyrroles necessary to produce porphyrins having the structure of FIG. 7 of the attached drawings where R is H or CHO, R10 through R12 are hydrogen, and each of R1 through R8 is
H or CHO,
a primary or secondary alkyl group having from 1 to 4 carbon atoms,
an alkylene group having from 2 to 4 carbon atoms,
a group having the formula R 2 N(R 3 ) 2 where R 2 is a bivalent aliphatic hydrocarbon radical having from 1 to 4 carbon atoms, wherein any carbon to carbon bond is either a single or a double bond, and not more than one is a double bond; R 3 is hydrogen or an alkyl radical having from 1 to 2 carbon atoms and the two R 3 groups can be the same or different,
a group having the formula R 2 N(R 4 ) 3 + where R 2 is a bivalent aliphatic hydrocarbon radical having from 1 to 4 carbon atoms, wherein any carbon to carbon bond is either a single or a double bond, and not more than one is a double bond; and R 4 is an alkyl group having from 1 to 2 carbon atoms and the three R 4 groups can be the same or different,
a group having the formula R 2 OH were R 2 is a bivalent aliphatic hydrocarbon radical having from 1 to 4 carbon atoms, wherein any carbon to carbon bond is either a single or a double bond, and not more than one is a double bond, or CO 2 R', CH 2 CO 2 R' or CH 2 CH 2 CO 2 R' where R' is H, or a primary or secondary alkyl group having from one to four carbon atoms, are all known or can be made by known methods. The nickel complex can be made by the method disclosed in Example 2, substituting the porphyrin for the benzochlorin and nickel acetate for zinc acetate. To produce benzochlorins, the alkoxycarbonylvinyl group, the β-hydroxyalkylvinyl group and the β-formylvinyl can then be introduced in the known way disclosed in Example 1 hereof. To produce verdins, a porphyrin starting material wherein at least one of R2, R3, R6 and R7 is CH 2 CH 2 COOR' is subjected to the procedure of Example 3. These porphyrins produce,
(a) when used in the procedure of Example 1, benzochlorins having the structure of FIG. 3 of the attached drawings where R10 through R12 and R14 are hydrogen, and,
(b) when used in the procedure of Example 3, verdins having the structure of FIG. 4 of the attached drawings where RIO through R12 are hydrogen
Such benzochlorins and verdins can be reacted with the Vilsmier reagent to introduce a formyl group, as R10 in the latter case or as R14 in the former. The formyl group, after separation of the isomers, if necessary, can be reduced to CH 3 , or can be reduced to CH 2 OH or converted to an oxime group, which can then be converted to a cyano group, which, in turn, can be converted to an amide. The formyl group can also be reacted with Wittig reagents to give alkyl, alkenyl or carboxy side chains or to introduce the previously identified substituents which have an amine or an alcoholic OH function in the R10 position. After the desired group has been introduced as R10, the benzochlorin or verdin can be reacted in the same way to introduce a desired group as R11. Finally, the chemistry can be used to introduce a desired group as R12. The metal complexes can be produced by the method of Example 2 or by modifications thereof which are subsequently discussed herein.
It will be appreciated that benzochlorins, verdins, porphyrin derivatives and metal complexes according to the invention where R10 through R12 are hydrogen are preferred, other factors being equal, because the production of the compounds with other groups in these positions is complicated, time consuming and expensive. The methods of Examples 8 and 9 are general in the sense that the former can be used to produce any porphyrin derivative having the structure of FIG. 9 from the corresponding purpurin while the latter can be used to produce any porphyrin derivative metal complex having the structure of FIG. 10 from the corresponding purpurin metal complex. The purpurins and purpurin metal complexes required to produce the porphyrin derivatives and porphyrin derivative metal complexes are disclosed in PCT/US86/02824.
The method of Example 2, supra, can be used to produce metal complexes of other benzochlorins, of porphyrin derivatives having the structure of FIG. 9, and of verdins. Specifically, an equivalent amount of another benzochlorin, of a porphyrin derivative, or of a verdin can be substituted for the octaethyl benzochlorin, or copper acetate, nickel acetate, cobalt acetate, silver acetate, palladium acetate, or platinum acetate can be substituted for the zinc acetate, or both substitutions can be made. In this manner, metal complexes having the formula of FIG. 1, of FIG. 2, of FIG. 5 or of FIG. 10, where M is one of the metals named above in this paragraph can be produced from the corresponding benzochlorins, verdins, or porphyrin derivatives. Other complexes can be produced by the method of Example 2 from salts containing cations other than acetate, and producing complexes which have the structures of FIGS. 1, 2 5 and 10, but where M does not represent merely a metal anion. Examples of salts that can be substituted for zinc acetate in the Example 2 procedure are identified below, together with the identity of M in FIGS. 2 and 5:
______________________________________Salt Identity of M______________________________________FeCl.sub.3 Fe(Cl)MnCl.sub.4 Mn(Cl)InCl.sub.3 In(Cl)VCl.sub.4 * V(O)Tl(CF.sub.3 CO.sub.2).sub.3 Tl(OAc)(H.sub.2 O)SnCl.sub.2 Sn(OH).sub.2[Rh(CO).sub.2 Cl].sub.2 Rh(Cl)(H.sub.2 O)______________________________________ *Using phenol as the solvent instead of glacial acetic acid.
The procedure of Example 2 can also be modified by substituting phenol for glacial acetic acid and metal chelates of pentane, 2,4-dione for zinc acetate to produce complexes of any of the benzochlorins, verdins or porphyrin derivatives. Metals that can be so reacted (as pentane, 2,4-dione chelates) and the identity of M in the complex that is produced are set forth in the following table:
______________________________________Metal Identity of M Metal Identity of M______________________________________Al Al(acac)* Th Th(acac).sub.2Sc Sc(acac) U U(acac).sub.2Ga Ga(acac) La La(acac.sub.2In In(acac) Ce Ce(acac)Mo Mo(acac) Nd Nd(acac)Ti Ti(acac).sub.2 Sm Sm(acac)Zr Zr(acac).sub.2 Gd Gd(acac)Hf Hf(acac).sub.2 Tb Tb(acac)Eu Eu(acac) Dy Dy(acac)Pr Pr(acac) Ho Ho(acac)Yb Yb(acac) Er Er(acac)Y Y(acac) Tm Tm(acac)Lu Lu(acac)______________________________________ *The pentane, 2,4dione portion of a chelate thereof with a metal.
Complexes of any of the foregoing benzochlorins, verdins and porphyrin derivatives can also be produced by the procedure of Example 2, substituting dimethylformamide for glacial acetic acid and CrCl 2 for zinc acetate. Metal complex formation occurs at higher temperatures when dimethylformamide is used, because of its higher boiling temperature. M in the complexes is Cr(OH).
Similarly, complexes of the foregoing benzochlorins, verdins and porphyrin derivatives can be produced by the procedure of Example 2, substituting pyridine for glacial acetic acid and PbCl 2 for zinc acetate. M in the complexes is Pb.
The preferred metal complexes according to the invention, because optimum results have been achieved therewith, are ones where M is Zn, Sn, Al, Ag, Ce or Ga.
The production of benzochlorin, verdin and porphyrin derivative solutions in the specific non-ionic solubilizer that is available under the designation CREMOPHOR EL, and the production of emulsions of such solutions with 1,2-propanediol and saline solution is described above, as is the use of such solutions to detect and treat tumors. It will be appreciated that benzochlorins, verdins, porphyrin derivatives and their metal complexes can be dissolved in other non-ionic solubilizers and that the solutions can be used to produce emulsions that can be administrated intravenously. For example, other reaction products of ethylene oxide and castor oil can be so used, as can reaction products of ethylene, propylene and other similar oxides with other fatty acids and the reaction products of propylene and other similar oxides with castor oil. Similarly, glycols other than 1,2-propanediol can be used in producing the emulsions for intravenous administration, or the glycol can be omitted, particularly if the solubilizer is prepared to have a lower viscosity and greater compatibility with water, by comparison with the solubilizer that is available under the designation CREMOPHOR EL. It is necessary only that the solution or emulsion be one which is physiologically acceptable and of a suitable concentration, or dilutable to a suitable concentration, for intravenous administration or for local administration, should that be desirable. An indefinitely large number of such solutions and emulsions will be apparent to those skilled in the relevant art from the foregoing specific disclosure. Similarly, the aqueous phase need not be 0.9 percent w/w or any other concentration of sodium chloride. Such saline is presently favored for intravenous administration, but other aqueous phases can also be used, so long as the entire composition is physiologically acceptable for intravenous administration and, in fact, other aqueous phases may subsequently be favored. Indeed, other aqueous phases or organic phases may also be favored for local administration.
Dosages ranging of 1 mg per kg of body weight were used in the in vivo procedures described above. It has been determined only that the biological consequences described above were caused by the dosages administered, not that any dosage reported is either a minimum or a maximum. It will be appreciated, therefore, that it is necessary only to use an effective amount of a benzochlorin, verdin, porphyrin derivative or metal complex according to the invention in the detection and treatment of tumors, preferably as small a dosage as possible, and that the exact dosage can be determined by routine experimentation. While systemic administration has been described above, specifically intravenous, it will also be appreciated that local administration will be suitable, at least in some instances.
Illumination of tumors containing a benzochlorin, a verdin, a porphyrin derivative or a metal complex in accordance with the instant invention can be a surface illumination with a conventional light source, as described above, or can be a surface illumination with a laser. The illumination can also be into the body of a tumor, for example through optical fibers inserted thereinto.
Various changes and modification can be made from the specific details of the invention as described above without departing from the spirit and scope thereof as defined in the appended claims. | A family of benzochlorins, a family of verdins, a family of porphyrin derivatives and metal complexes thereof are disclosed. The benzochlorins have the formula of FIG. 3 of the attached drawings; their metal complexes have the formula of FIG. 1. The verdins have the formula of FIG. 4 of the attached drawings; their metal complexes have the formula of FIG. 2. The porphyrin derivatives have the formula of FIG. 9 of the attached drawings; their metal complexes have the formula of FIG. 10. Solutions of the benzochlorins, verdins, porphyrin derivatives and metal complexes which are physiologically acceptable for intravenous administration are also disclosed, as are emulsions or suspensions of the solutions, and compositions which additionally include cyclodextrin, and wherein the molecules of the benzochlorin, verdin, porphyrin derivatives or metal complex are encapsulated within the molecules of the cyclodextrin. The solvent for the solutions can be a product of the reaction of ethylene oxide with castor oil. A method for detecting and treating tumors in human and animal patients is also disclosed. The method comprises administering one of the benzochlorins, verdins, porphyrin derivatives or metal complexes to the patient. For detection, the tumor area is then illuminated with ultra violet light; for treatment, the tumor area is illuminated with visible light of a wavelength at which the benzochlorin, verdin, porphyrin derivatives or complex administered shows an absorption peak. | 2 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a divisional of U.S. patent application Ser. No. 11/307,923 filed Feb. 28, 2006, the disclosure of which is hereby incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] The invention relates to latch circuits, and more particularly to a method of testing connectivity using latch signals which are transmitted as differential pairs of signals.
[0003] Latches take a variety of forms and are used in a variety of applications. Latches are basic building blocks of many types of sequential digital circuits including flip-flops, registers, adders, multipliers, etc., and are used at interfaces between digital circuits and analog circuits. In its simplest form, a binary digital latch is implemented by a circuit which generates an output signal having one of two binary states determined in accordance with a state of at least one input signal. A clock signal times the operation of the binary latch such that the output signal transitions between states at times determined in accordance with the clock signal.
[0004] A current mode logic (“CML”) latch is a particular type of latch which is usable when signals are transmitted as differential pairs of signals. Signals transmitted at relatively high frequencies require noise rejection to a greater degree than signals transmitted at lower frequencies. One way to achieve greater noise rejection is to transmit one signal differentially as a pair of signals which have opposite states. In each such pair, the differential signals either remain together at their respective opposite states or swing between the opposite states simultaneously. Data-carrying signals are input to a CML latch as a pair of differential data signals. Clock signals are input to the CML latch as a pair of differential clock signals. A CML latch rejects noise that affects (e.g., slows, advances, raises or lowers) both of the differential signals in the same way so as to latch the output signal reliably at a correct state despite noise affecting the differentially transmitted pair of signals. With differential signal transmission, even in the presence of noise, the differential clock signals accurately time the operation of the CML latch and the CML correctly latches the states of the differential data signals.
[0005] FIG. 1 is a schematic diagram illustrating a CML latch 100 in accordance with the prior art. As illustrated in FIG. 1 , the CML latch 100 includes a first input device 102 and a second input device 104 , the first and second input devices being operable to receive first and second differentially transmitted input signals AP and AN, respectively. A first tail device 110 controls the flow of current between the first and second input devices and a current source 114 which is connected to ground. The first and second input devices 102 , 104 become active when one clock signal CP input to the first tail device 110 is active. Such clock signal CP is one of a pair of differential clock signals CP and CN having phases 180 degrees apart, the clock signals swinging simultaneously between opposite levels. The differential clock signals operate at a relatively high frequency, such as a frequency of a few hundred megahertz (MHz) to several gigahertz (GHz) or tens of gigahertz.
[0006] When clock signal CP is active, one of the first and second input devices conducts a current I 1 or I 2 , respectively, in accordance with the states of the first and second input signals AP and AN, respectively. The states of output signals ZP and ZN change according to the currents I 1 and I 2 across loads L 1 and L 2 , respectively. In such way, when input signal AP is active, current I 1 across load L 1 pulls down the voltage at node ZN such that the output signal ZN becomes low. The input signal AN at such time is inactive, causing input device 104 to be turned off. In that case, current I 2 does not flow and the output signal at node ZP remains high. On the other hand, when input signal AN is active, current I 2 across load L 2 pulls down the voltage at node ZP such that the output signal ZP becomes low. At such time, the input signal AP is inactive, causing input device 102 to be turned off such that current I 1 does not flow and the output signal at node ZN remains high.
[0007] A pair of cross-coupled devices 106 and 108 are operable to latch the output signals ZP and ZN when the differential clock signal CN is active. When clock signal CP is active, the clock signal CN is inactive, such that output signals ZP and ZN change when the input signals AN and AP change. On the other hand, when clock signal CP is inactive and the clock signal CN is active, the cross-coupled devices 106 , 108 latch the current states of the output signals ZP and ZN and hold them until clock signal CP becomes active again.
[0008] One problem of the CML latch 100 is that it is only usable when the differential clock signals CP and CN are active. The high switching frequency of these clock signals precludes them from being supplied to the CML latch by any means other than internal generation on an integrated circuit (“IC”) or chip which incorporates the CML latch or on a card to which the chip is mounted. Signals cannot be propagated through the CML latch unless the differential clock signals are present.
[0009] However, it is desirable to test chips which include CML latches at times when it is not possible to supply the differential clock signals CP and CN to the latches.
SUMMARY OF THE INVENTION
[0010] In accordance with an embodiment of the invention, a method of testing connectivity through a plurality of dual purpose current mode logic (“CML”) latch circuits connected in a series is provided. Each of the CML latch circuits are operable to latch at least one output signal at a timing in accordance with at least one clock signal and having a mode control device for operating the CML latch circuit as a buffer amplifier when the at least one clock signal is inactive. The method comprises the steps of activating the mode control devices of each of the CML latches to operate each of the CML latches as a buffer; inputting a first signal to a first CML latch of the series; latching an output signal of a second CML latch of the series, the second CML latch being connected at a point in the series downstream from the first CML latch; and determining whether the output signal changes in accordance with a change in the first signal.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a schematic diagram illustrating a current mode logic (“CML”) latch in accordance with the prior art.
[0012] FIG. 2 is a schematic diagram illustrating a CML latch circuit in accordance with a first embodiment of the invention.
[0013] FIG. 3 is a schematic diagram illustrating a CML latch circuit in accordance with a particular embodiment of the invention in which active devices include n-type field effect transistors (“NFETs”).
[0014] FIG. 4 is a schematic diagram illustrating a variation of the CML latch circuit shown in FIG. 3 , in which active load devices are utilized in place of resistors.
[0015] FIG. 5A is a schematic diagram illustrating a CML latch circuit in accordance with a particular embodiment of the invention in which active devices include p-type field effect transistors (“NFETs”).
[0016] FIG. 5B is a schematic diagram illustrating a variation of the CML latch circuit shown in FIG. 5A , in which active load devices are utilized in place of resistors.
[0017] FIG. 6A is a schematic diagram illustrating a CML latch circuit in accordance with a particular embodiment of the invention in which active devices include npn type bipolar transistors.
[0018] FIG. 6B is a schematic diagram illustrating a variation of the CML latch circuit shown in FIG. 6A , in which active load devices are utilized in place of resistors.
[0019] FIG. 6C is a schematic diagram illustrating a CML latch circuit in accordance with a particular embodiment of the invention in which active devices include pnp type bipolar transistors.
[0020] FIG. 6D is a schematic diagram illustrating a variation of the CML latch circuit shown in FIG. 6C , in which active load devices are utilized in place of resistors.
[0021] FIG. 7 is a block and schematic diagram illustrating a serializer circuit including a plurality of CML latches in accordance with an embodiment of the invention, as operated in a normal operational mode.
[0022] FIG. 8 is a block and schematic diagram illustrating operation of a serializer circuit in a test mode, the serializer circuit being arranged in accordance with the embodiment of the invention illustrated in FIG. 7 .
DETAILED DESCRIPTION
[0023] A dual purpose current mode logic (“CML”) latch circuit in accordance with an embodiment of the invention includes a CML latch and a mode control circuit. The CML latch is operable to receive a pair of differential input data signals and a pair of differential clock signals and is operable to generate at least one output signal in accordance with the states of the pair of differential input data signals. A mode control signal applied to the mode control circuit which determines whether the CML latch operates as a latch or as a buffer. Thus, when the clock signal is present, the CML latch can be operated in a normal operational mode to generate and latch the output signal in accordance with the differential input data signals that are applied to it at a timing determined by the clock signal. On the other hand, when the clock signal is not present, a mode control signal can be activated for operating the CML latch circuit in a test mode. In such test mode, the CML latch generates the output signal in accordance with the state of the differential input data signals but operates like a buffer instead of a latch. When the CML operates as a buffer, the output signal changes whenever the states of the differential input data signals change.
[0024] Each of the CML latches described herein in accordance with the various embodiments of the invention has dual operational modes. In the first operational mode in which the clock signal is supplied to the CML latch, the CML latch latches the output signal at a timing determined by the state of the clock signal. In the second operational mode, the CML latch operates as a buffer during a test mode when the clock signal normally supplied thereto is absent. In this way, during production testing, the CML latch can be operated as a buffer while testing electrical continuity of circuits which include the dual mode CML latch. For example, the CML latch can be operated as a buffer during wafer-level or chip-level production testing prior to packaging the chip when it is technologically forbidding or inconvenient to supply a high switching frequency clock signal to the chip.
[0025] FIG. 2 is device-level schematic diagram illustrating a CML latch circuit 210 in accordance with an embodiment of the invention. As shown in FIG. 2 , the CML latch circuit 210 includes a CML latch 100 such as that shown and described above with reference to FIG. 1 . The CML latch circuit also includes a mode control circuit 201 including a mode control device 202 which is connected in parallel with the first tail device 110 of the CML latch. In the particular example shown in FIG. 2 , the mode control device 202 is connected between a first node 200 and a second node 220 , the second node 220 being directly connected to a current source 114 . In such way, the mode control device provides an alternative path for the flow of current between the input devices 102 , 104 and the current source 114 , thus eliminating the need for a first differential clock signal CP to be provided to the first tail device. During a normal operational mode, an LTEST signal at the input to the mode control circuit is held inactive such that differential clock signals CP and CN provided to inputs of the first and second tail devices 110 and 112 control the operation of the CML latch 100 . The second clock signal CN has the same clock frequency and the same voltage levels as the clock signal CP but is an inverted version of clock signal CP. While in the normal operational mode, during a first phase of a cycle of the differential clock signals, a first differential clock signal CP is active and a second differential clock signal CN is inactive. During the first phase of the differential clock cycle, the CML latch 100 begins to generate the output signals ZN and ZP in accordance with the signals AP and AN applied to input devices 102 , 104 . Subsequently, during a second phase of the differential clock cycle, the first differential clock signal CP is inactive and the second differential clock signal CN is active. During the second phase, the cross-coupled devices 106 , 108 amplify the difference between the output signals ZN and ZP at that time and latch the states of the output signals until the first phase of the next differential clock cycle begins.
[0026] During a test mode of operation, the first and second differential clock signals are not supplied to the CML latch as input to the first and second tail devices 110 , 112 . Instead, the voltage or current at the second differential clock signal input CN at the input to the second tail device 112 is held constant at a level to maintain tail device 112 active. In addition, an active level is supplied at the LTEST signal input to the mode control circuit 201 . The voltage or current at the input to the first differential clock signal input CP can be either left to float or held constant in an inactive state. Under such conditions, the CML latch generates differential output signals ZP and ZN according to the states of the differential input signals AN and AP, respectively. It is not necessary for the differential clock signals CP and CN to be provided to the CML latch 100 at that time. The output signals ZP and ZN generated by the CML latch 100 change in accordance with the input signals AN and AP as quickly as the input devices 102 , 104 and the cross-coupled devices 106 , 108 are able to amplify the input signals AN and AP. Thus, during the first operational mode, the CML latch circuit 210 operates as a latch timed in accordance with the pair of differential clock signals CP and CN. Otherwise, during the test mode, the CML latch 210 operates as a buffer when the LTEST signal and a voltage or current provided at the CN input to the second tail device are held in the active state.
[0027] FIG. 3 illustrates a CML latch circuit 310 in accordance with a particular embodiment of the invention. This embodiment is the same as that described above with respect to FIG. 2 , except that the mode control device 301 , the input devices 302 , 304 , the cross-coupled devices 306 , 308 , and the tail devices 312 and 314 are specified to be n-type field effect transistors (“NFETs”). The input signals, output signals and operation of the CML latch circuit 310 are the same as that described above with respect to FIG. 2 .
[0028] FIG. 4 illustrates a CML latch circuit 330 according to a variation of the above-described CML latch circuit ( 310 ; FIG. 3 ). In such CML latch circuit 330 , p-type field effect transistors (“PFETs”) function as active load devices 320 , 322 , having drain terminals connected in conductive paths to drain terminals of the NFET input devices 302 , 304 . A bias voltage VB applied to the gates of the active load devices 302 , 304 controls the conductivity of the load devices, and hence, the voltage drop across each of them according to the voltages of the respective input signals AP and AN applied to the input devices. The bias voltage can be held constant or modulated according to the operating conditions of the CML latch and the chip on which it is implemented. In a particular embodiment, the bias voltage VB is generated in accordance with a stable reference voltage such as a bandgap voltage and is applied to the load devices 320 , 322 through a current mirroring arrangement. In such manner, the bias voltage may compensate for variations in the manufacturing process that affect the particular chip as well as changes in the operating environment such as temperature and operating loads.
[0029] FIG. 5A illustrates a CML latch circuit 510 according to further variation of the above-described CML latch circuit 210 . In this variation, p-type field effect transistors (“PFETs”) are utilized as the mode control device 501 , the input devices 502 , 504 , the cross-coupled devices 506 , 508 , and the tail devices 512 and 514 . In contrast to the embodiment illustrated in FIG. 2 , in this embodiment the clock signal CN is input to the tail device 512 which sources current to the input devices 502 , 504 . Clock signal CP is input to the tail device 514 which sources current to the cross-coupled devices 506 , 508 . Operation of the CML latch circuit 510 is the same as that described above with respect to FIG. 2 , noting that the input data signals AP, AN, the clock signals CN and CP and the /LTEST signal input thereto are active when at a lower voltage level rather than when at a higher voltage level.
[0030] In a manner like that shown and described above with respect to FIG. 4 , active load devices 520 , 522 can also be utilized in the CML latch circuit 530 ( FIG. 5B ) in place of the resistors R 1 , R 2 ( FIG. 5A ).
[0031] FIG. 6A illustrates a CML latch 610 circuit according to yet another variation in which each of the mode control device 601 , input devices 602 , 604 and cross-coupled devices 606 , 608 and tail devices 612 , 614 of a are implemented as npn-type bipolar transistors. Operation is the same or similar to that described above with respect to the NFET embodiment 310 illustrated in FIG. 3 . In a CML latch circuit 620 ( FIG. 6B ) according to a variation of the embodiment shown in FIG. 6A , pnp type active load devices 625 , 627 or other appropriate active load devices are utilized in place of the load resistors R 1 and R 2 .
[0032] FIG. 6C illustrates a CML latch circuit 630 according to a further variation in which each of the mode control device 631 , input devices 632 , 634 and cross-coupled devices 646 , 648 and tail devices 642 , 644 are implemented as pnp-type bipolar transistors. Operation is similar if not functionally nearly the same as that described above with respect to the PFET embodiment 510 illustrated in FIG. 5A . In a CML latch circuit according to a further variation 650 ( FIG. 6D ), npn type active load devices 535 , 537 or other appropriate active load devices are utilized in place of the load resistors R 1 and R 2 .
[0033] FIG. 7 is a block and schematic diagram illustrating a serializer circuit 700 in accordance with a further embodiment of the invention. The serializer circuit incorporates CML latch circuits in accordance with any one or more of the embodiments described above with respect to FIGS. 2 through 6D . Specifically, each of the flip-flops and latches in the serializer circuit 700 includes a CML latch according to one of the above-described embodiments. The serializer circuit 700 is used to convert a stream of parallel data into a serial data stream, such as for the purpose of transmitting data over a serial data transmission link. One bit data signals D 0 , D 1 , D 2 and D 3 are input to respective ones of the flip-flops 710 , 711 , 712 and 713 , each of the flip-flops including a CML latch in accordance with one of the embodiments described above with reference to FIGS. 2 through 6D . The output of certain flip-flops 711 and 713 are input to latches 714 , which themselves are CML latch circuits having a structure and operating in accordance with one of the embodiments described above with reference to FIGS. 2 through 6D .
[0034] In an example of operation, a full rate clock signal (C 1 ) including a pair of differential clock signals is input to the serializer 700 at a frequency of 6.4 GHz and is buffered and supplied to the serializer circuit as the differential pair of clock signals 742 . A synchronous divider 724 divides that clock frequency in half to 3.2 GHz for input as a differential pair of clock signals to second stage flip-flops 718 , latch 720 and as a select signal to multiplexer 722 . In addition, the synchronous divider 724 outputs another pair of differential clock signals 746 at a divided down clock frequency of 1.6 GHz. This pair of differential clock signals provides the CP and CN clock inputs to first stage flip-flops 710 , 711 , 712 , and 713 . A clock converter circuit 726 converts the divided down differential clock signal 746 to a single-ended clock signal 750 at the same frequency (1.6 GHz) for output to rail-to-rail logic circuits on the chip, for example CMOS logic circuits. The rail-to-rail logic circuits utilize the divided down single-ended clock signal 727 for control of sequential logic circuits, including logic circuits which produce the input data signals D 0 , D 1 , D 2 and D 3 . The data signals D 0 , D 1 , D 2 and D 3 preferably are single-ended and the flip-flops 710 , 711 , 712 and 713 convert these single-ended data signals to respective pairs of differential signals,
[0035] As timed by the pair of differential clock signals 746 , the flip-flops 710 , 711 , 712 , 713 latch the input data signals D 0 , D 2 , D 1 and D 3 , respectively, into the serializer 700 as pairs of differential data signals. In addition, the pair of differential clock signals 746 are input as a select signal to the multiplexers 716 in the first stage of the serializer circuit 700 .
[0036] One of the multiplexers 716 , operated by a clock signal 750 , selects alternating ones of data bits D 0 and 10 D 2 input thereto through flip-flops 710 , 711 and latch 714 , and another one of the multiplexers 716 selects alternating ones of the data bits D 1 and D 3 input thereto through flip-flops 712 , 713 and latch 714 . The output of the multiplexers 716 are input through flip-flops 718 and latch 720 to a further multiplexer 722 that operates with the differential pair 744 of clock signals at twice the rate of the clock signal 750 supplied to the multiplexers 716 . Finally, the data output by multiplexer 722 is latched by the pair 742 of differential clock signals into a series of serially connected flip-flops 730 , 732 , 734 , 736 and 738 at the final (undivided) clock rate to obtain the serialized data signal.
[0037] Each of the flip-flops 732 , 734 , 736 , and 738 in the series includes two latches so as to produce two outputs, each output as a pair of differential signals. Each of the outputs of the flip-flops is delayed by 0.5 cycles of the differential clock in relation to one other output of the series of flip-flops, except for the output Z 0 of flip-flop 732 which is the first output in the series. Thus, output Z 05 is delayed by 0.5 cycles of the differential clock in relation to output Z 0 and output Z 1 is delayed by 0.5 cycles of the differential clock in relation to output Z 05 , and so on among all the outputs of the flip-flops 732 . In such way, the outputs Z 0 , Z 05 , Z 1 , Z 15 , Z 2 , Z 25 , Z 3 and Z 35 of the flip-flops are taps of a tapped delay line. These taps are provided to a finite impulse response (“FIR’) transmitter, which in turn, is used to shape the serialized data stream signal for transmission over a serial data transmission link (not shown).
[0038] During a particular mode of operation, a demultiplexer 740 also receives outputs Y 0 , Y 1 , Y 2 and Y 3 of the flip-flops 732 , 734 , 736 and 738 , respectively, these preferably being the same signals as provided at the outputs Z 0 , Z 1 , Z 2 and Z 3 . The demultiplexer is operable to output four bits of parallel data at the original parallel clock signal rate (1.6 GHz) as wrap data during a particular test mode.
[0039] During a test mode of the chip for performing continuity testing, the LSSD test signal is activated to each of the CML latches of the serializer circuit, in a manner as shown in FIG. 2 , for example. Referring to FIG. 8 , as a result, each of the CML latches, including each of the flip-flops and latches in the serializer circuit 700 now operates as a buffer or as a pair of series-connected buffers instead of a flip-flop or a latch. Each of the flip-flops 710 , 711 , 712 , and 713 and latches 714 operates as a buffer. Each of the flip-flops 730 , 732 , 734 , 736 and 738 operates as a pair of series-connected buffers.
[0040] During the test mode of operation, a latch, preferably a “level sensitive scan device” (LSSD) latch 765 , also referred to as a “shift register latch” (SRL), provides a data bit signal at the input to the serializer circuit 700 . In place of the clock signal, a pair of select signals LSSDS 0 and LSSDS 1 are input to the serializer for selecting a particular one of the digital bits D 0 , D 1 , D 2 or D 3 to be passed between the input and the output of the serializer circuit. After modification by logic 770 and/or the converter circuit 726 , these select signals LSSDS 0 and LSSDS 1 are applied to the select inputs of the multiplexers 716 and 720 . Thus, the LSSDS0 and LSSDS1 signals control the selection of signals through the multiplexers 716 and 720 . Specifically, the digital bit that is selected by the multiplexers appears at the flip-flop 730 in accordance with the following truth table:
[0000]
TABLE 1
Bit Selection Truth Table
LSSDS0
LSSDS1
Bit
0
0
D3
0
1
D1
1
0
D0
1
1
D2
[0041] Such signal propagates through the flip-flops 732 , 734 , 736 and 738 to an output of the serializer circuit through a final buffer 760 as an “observe signal” which is latched by an SRL latch 762 . In addition, outputs of the flip-flops propagate through the demultiplexer 740 and are latched by an SRL latch 764 .
[0042] While the CML latches are operated as buffers in the test mode, a signal applied as input to the serializer circuit at one of the data bit inputs D 0 through D 3 propagates through the serializer circuit without requiring a clock signal to be present. At that time, the states of the select signals LSSDS 0 and LSSDS 1 determine which of the data bit inputs D 0 through D 3 is passed through to the outputs through buffer 760 as the “observe” signal or through the demultiplexer 740 .
[0043] While the invention has been described in accordance with certain preferred embodiments thereof, many modifications and enhancements can be made thereto without departing from the true scope and spirit of the invention, which is limited only by the claims appended below. | A method of testing connectivity through a plurality of dual purpose current mode logic (“CML”) latch circuits connected in a series is provided. Each of the CML latch circuits are operable to latch at least one output signal at a timing in accordance with at least one clock signal and having a mode control device for operating the CML latch circuit as a buffer amplifier when the at least one clock signal is inactive. The method comprises the steps of activating the mode control devices of each of the CML latches to operate each of the CML latches as a buffer; inputting a first signal to a first CML latch of the series; latching an output signal of a second CML latch of the series, the second CML latch being connected at a point in the series downstream from the first CML latch; and determining whether the output signal changes in accordance with a change in the first signal. | 7 |
FIELD OF INVENTION
[0001] The present invention relates to a method and a device for diagnosing at least one gas exchange valve of at least one cylinder of an internal combustion engine.
BACKGROUND INFORMATION
[0002] German Patent Application No. DE 10 2005 049 777 A1 describes a method and a device for operating an internal combustion engine. Here, in at least one operating state of the internal combustion engine, at least one intake or exhaust valve of a cylinder of the internal combustion engine is switched off, or at least one switched-off intake or exhaust valve of the cylinder is reactivated. Thus, for example, a first operating state of the internal combustion engine can be provided by switching off half of the cylinders by switching off the intake or exhaust valves, as well as by switching off the fuel injection. This first operating state is also called half engine operation. In the case in which cylinders are switched off, in half engine operation, half the cylinders are switched off by switching off the intake and exhaust valves as well as the fuel injection. In a second operating state of the internal combustion engine, for example, all the cylinders are then reactivated, i.e., their intake and exhaust valves and the fuel injection are reactivated. This second operating state is also called full engine operation.
[0003] The time at which a deactivation or activation, i.e., a switching off or a switching back on, of an intake or exhaust valve (also called a gas exchange valve) can take place is limited by the basic circuit of the camshaft, because only then is the corresponding gas exchange valve closed, in the forceless idle state.
SUMMARY OF THE INVENTION
[0004] The method and the device according to the present invention for diagnosing at least one gas exchange valve of at least one cylinder of an internal combustion engine have an advantage that sound waves produced by the internal combustion engine are acquired and that it is checked whether, upon transition from the first operating state to the second operating state, a significant change occurs in a quantity that characterizes the acquired sound waves. In this case, an erroneous opening of the at least one gas exchange valve is recognized. This creates a simple and reliable means of diagnosing an erroneous opening of the at least one gas exchange valve, which in addition can be realized using already-present sensor equipment, thus avoiding the need for additional sensor equipment.
[0005] The diagnosis according to the present invention can be carried out in a particularly simple manner if an amplitude or an intensity of the acquired sound waves is evaluated as the quantity characterizing the acquired sound waves. These quantities can be determined without great expense, for example from the signal provided by a structure-borne sound sensor.
[0006] The diagnosis can then take place in a simple manner by comparing the amplitude or the intensity of the acquired sound waves to a prespecified threshold value, and recognizing the erroneous opening of the at least one gas exchange valve as a function of the result of the comparison, preferably if the prespecified threshold value is exceeded by the amplitude or the intensity of the acquired sound waves.
[0007] A particularly reliable diagnosis of an erroneous opening of the at least one gas exchange valve is achieved by evaluating at least one frequency, or a frequency spectrum, of the acquired sound waves as the quantity characterizing the acquired sound waves.
[0008] In this case, the diagnosis can easily be realized by checking whether the acquired sound waves have at least one prespecified frequency portion lying above a prespecified threshold, and by recognizing in this case an erroneous opening of the at least one gas exchange valve.
[0009] It is particularly advantageous if the sound waves are acquired by a structure-borne sound sensor. In this way the sound waves can be reliably acquired, and a structure-borne sound sensor is as a rule already present in modern internal combustion engines for other evaluative purposes, such as the recognition of misfires, so that the diagnosis according to the present invention does not require any additional sensor equipment.
[0010] The reliability of the diagnosis can be increased by recognizing the erroneous opening of the at least one gas exchange valve only if the significant change in the quantity characterizing the acquired sound waves takes place within a prespecified time from the activation, or request for activation, of the second operating state, starting from the first operating state.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIGS. 1 a through 1 c show the operation of a cylinder of an internal combustion engine given an intake valve closed in error-free fashion.
[0012] FIGS. 2 a through 2 c show the operation of the cylinder with the intake valve at first closed and subsequently opened in erroneous fashion, FIG. 2 c also showing additional devices for receiving and evaluating sound waves produced by a cylinder.
[0013] FIG. 3 shows a functional diagram of an exemplary device according to the present invention.
[0014] FIG. 4 shows a sequence diagram of an exemplary method according to the present invention.
DETAILED DESCRIPTION
[0015] FIG. 1 a schematically shows a longitudinal section through a cylinder 2 of an internal combustion engine. The internal combustion engine can be fashioned for example as a gasoline engine or as a diesel engine. Cylinder 2 includes a combustion chamber 10 . Fresh air, possibly together with fuel, is capable of being supplied to combustion chamber 10 via at least one intake valve 3 . The exhaust gas formed during the combustion of the air/fuel mixture in combustion chamber 10 can be carried out of combustion chamber 10 via at least one exhaust valve 4 . The combustion of the air/fuel mixture in combustion chamber 10 causes a piston 1 of cylinder 2 to move up and down, thus driving, via a connecting rod 12 , a crankshaft of the internal combustion engine (not shown in FIG. 1 a for simplicity).
[0016] Cylinder 2 of the internal combustion engine can be operated in different operating states. In a first operating state of the internal combustion engine, the at least one intake valve 3 and the at least one exhaust valve 4 are activated. That means for example that in an intake stroke of cylinder 2 the at least one intake valve 3 is opened in order to suction in fresh air, and possibly fuel, and the at least one exhaust valve 4 is closed. Alternatively, the fuel may also be injected directly into combustion chamber 10 . During a compression stroke of cylinder 2 , the at least one intake valve 3 and the at least one exhaust valve 4 are then closed. The same also holds for a subsequent combustion stroke. In the subsequent exhaust stroke, the at least one intake valve 3 is then closed and the at least one exhaust valve 4 is then opened. This valve actuation represents only an example of an operation of cylinder 2 with activated intake and exhaust valves 3 , 4 . Such operation is characteristic for example of a four-stroke engine in full engine operation, in which all the cylinders of the internal combustion engine are operated in the described manner.
[0017] A second operating state of the internal combustion engine is characterized in that all the intake and exhaust valves 3 , 4 of cylinder 2 are deactivated and are thus closed in stationary fashion. This means that during all previously described strokes of cylinder 2 in the second operating state all the intake and exhaust valves 3 , 4 of cylinder 2 are closed. This is required for example in half engine operation of the internal combustion engine, in which only half the cylinders of the internal combustion engine are operated with activated intake and exhaust valves, while the other half of the cylinders are not operated; i.e., all the intake and exhaust valves of this cylinder are permanently closed during this operating state, and no supply of fuel takes place.
[0018] FIGS. 1 a through 1 c show the operation of cylinder 2 in the second operating state, all the intake and exhaust valves 3 , 4 of cylinder 2 being closed at the beginning of and during this second operating state in stationary fashion, i.e. permanently. In FIG. 1 a , piston 1 moves upward in cylinder 2 . Due to the last combustion in the combustion chamber of cylinder 10 in the previous, first operating state of the internal combustion engine, the combusted exhaust gas 5 is compressed as internal energy U in combustion chamber 10 of cylinder 2 by the upward movement of piston 1 , and is not ejected through closed intake and exhaust valves 3 , 4 .
[0019] FIG. 1 b shows top dead center of piston 1 in cylinder 2 , in which the combusted exhaust gas 5 is compressed to the smallest, minimal space. This results in pressures between, for example, 20 and 40 bar. Because intake and exhaust valves 3 , 4 continue to be directly deactivated and are therefore closed, combusted exhaust gas 5 essentially cannot escape.
[0020] FIG. 1 c shows the subsequent downward movement of piston 1 in cylinder 2 . This movement causes compressed exhaust gas 5 to relax, and internal energy U of the combusted exhaust gas is used to move piston 1 downward. Here, intake and exhaust valves 4 of cylinder 2 continue to be deactivated and therefore closed, because the second operating state continues to obtain. Thus, internal energy U of the combusted exhaust gas in combustion chamber 10 realizes a gas spring that causes piston 1 to execute upward and downward movement. The movement of piston 1 downward according to FIG. 1 c takes place due to the recovery of energy from the gas spring that is compressed at top dead center of piston 1 according to FIG. 1 b.
[0021] FIGS. 2 a through 2 c show the case in which, in the second operating state, the at least one intake valve 3 opens in erroneous fashion. First, and at the beginning of the second operating state of the internal combustion engine, intake and exhaust valves 3 , 4 are completely closed, because (according to FIG. 2 a , which corresponds to FIG. 1 a ) piston 1 moves upward so that the cylinder is in the compression stroke. Here, the at least one intake valve 3 and the at least one exhaust valve 4 are closed if in FIG. 2 b , which corresponds to FIG. 1 b , piston 1 has reached its top dead center and the combusted exhaust gas 5 is maximally compressed.
[0022] If, in the subsequent compression stroke according to FIG. 2 c , in which piston 1 moves downward again, the at least one intake valve 3 and/or the at least one exhaust valve 4 open in erroneous fashion as a result of a defect, combusted exhaust gas 5 escapes, so that internal energy U escapes from combustion chamber 10 abruptly, via the incorrectly opened valve or valves. The defect can be a mechanical defect of the camshaft that drives the at least one intake valve 3 or the at least one exhaust valve 4 . In the case of an electromagnetic or electrohydraulic valve controller, the defect can also be a defect of this electromagnetic or electrohydraulic valve controller that incorrectly opens the at least one intake valve 3 and/or the at least one exhaust valve 4 .
[0023] Internal energy U or combusted exhaust gas 5 escapes from combustion chamber 10 in a manner similar to a detonation, and produces sound waves, for example in the form of structures borne sound waves. Acoustically, this escape can clearly be heard as mechanical noise, comparable to the impact of a hammer against the engine block. The sound waves are identified in FIG. 2 c by reference character 14 , and are transmitted via engine compartment 11 and engine block 15 , in which there is situated a sensor 16 , for example a structure-borne sound sensor, that picks up these sound waves 14 . Structure-borne sound sensor 16 is connected to a control device 18 via an information line 17 . Control device 18 receives the data via the sound waves 14 from structure-borne sound sensor 16 , and evaluates them. If sound waves 14 occur directly after, or within a prespecified time after, the activation of the second operating state, the erroneous opening of the at least one intake valve 3 and/or of the at least one exhaust valve 4 is recognized. The high internal energy U can be produced only during the activation of the second operating state, i.e. immediately after the end of the previous, first operating state. After sound waves 14 have been produced by the escape of internal energy U from combustion chamber 10 , almost no energy is left in cylinder 2 . After 720° of crankshaft angler the case shown in FIG. 2 c is repeated mechanically, but a high internal energy no longer escapes. Thus, the probability of the production of a sound wave, as a function inter alia of the geometry of the piston compartment, is lower. The described diagnostic possibility is therefore possible only directly after the activation of the second operating state, i.e. only during the first 720° of crankshaft angle after the activation or changeover from the first operating state to the second operating state, for the case under consideration here of a four-stroke engine.
[0024] FIG. 3 shows a functional diagram of an exemplary device according to the present invention for diagnosing the at least one intake valve 3 and/or the at least one exhaust valve 4 of the at least one cylinder 2 of the internal combustion engine, which can be implemented for example in terms of software and/or in terms of hardware in engine control unit 18 . For simplicity, therefore, in the following the device for diagnosis will be regarded as equivalent to control device 18 . However, in general control device 18 is the engine control device, which also performs functions other than the diagnosis according to the present invention.
[0025] Device 18 includes an evaluation unit 25 to which the signal from structure-borne sound sensor 16 is supplied via information line 17 . Evaluation unit 25 evaluates the signal from structure-borne sound sensor 16 , which signal provides an image of sound waves 14 received by structure-borne sound sensor 16 , with regard to one or more quantities that characterize acquired sound waves 14 . These quantities can be for example an amplitude of the sound waves, or the sound pressure level of the sound waves, a sound intensity, or a sound power. This quantity or quantities are each compared, in a comparator unit 20 , with a prespecified threshold value obtained from a threshold value storage unit 35 .
[0026] If the quantity from structure-borne sound sensor 16 evaluated by evaluation unit 25 exceeds the allocated prespecified threshold value from threshold value storage device 35 , or, in the case of the evaluation of a plurality of different quantities, all these quantities exceed their respectively allocated threshold value, comparator unit 20 outputs a set signal at its output as an error signal, indicating the recognition of an erroneous opening of the at least one intake valve 3 and/or of the at least one exhaust valve 4 . Otherwise, i.e. if the quantity represented by the signal from structures borne sound sensor 16 evaluated by evaluation unit 25 does not exceed the allocated prespecified threshold value, or, in the case of a plurality of quantities of the signal of structure-borne sound sensor 16 evaluated by evaluation unit 25 , at least one of the evaluated quantities does not exceed its allocated prespecified threshold value, error signal F is not set, so that no error is recognized.
[0027] In the case of a recognized error, this error can for example be displayed on a display unit. As an error reaction measure, emergency operation of the internal combustion engine may also be introduced, with reduced power or, as a final consequence, shutting off of the internal combustion engine.
[0028] In addition, a time element 30 is provided in device 18 to which a signal is supplied from a request unit 40 . Request unit 40 determines, as a function of the current operating point of the internal combustion engine, whether the first operating state or the second operating state should be set, i.e., for example, whether full engine operation or half engine operation should be set. If, starting from the first operating state, request unit 40 determines that the second operating state should be set, it forms a corresponding request signal with which, for example in the case of an electromagnetic or an electrohydraulic valve controlling, all the intake and exhaust valves of the cylinders that are to be switched off for the second operating state are to be deactivated and thus rendered stationary or permanently closed. In FIG. 3 , this signal is identified by reference character A, and is also supplied to time element 30 . Upon the receipt of the request signal for the changeover from the first operating state to the second operating state, time element 30 is started, and outputs, beginning from the reception of request signal A until the expiration of a prespecified time (corresponding for example to a crank angle interval of 720° in addition to the required reaction time from the generation of request signal A until the deactivation of the named intake and exhaust valves), a release signal to comparator unit 20 , and otherwise outputs a blocking signal. As long as comparator unit 20 receives the release signal, it carries out the described comparison and the corresponding formation of error signal F; otherwise it outputs as error signal F a signal that has been reset. In order to determine the prespecified time corresponding to the crank angle of 720°, time element 30 is also to be provided with the current rotational speed of the internal combustion engine; however, for reasons of clarity this is not shown in FIG. 3 , and is in any case known to those skilled in the art.
[0029] In addition to, or alternatively to, the named quantities evaluated by evaluation unit 25 from the signal of structure-borne sound sensor 16 , evaluation unit 25 can also evaluate at least one frequency, or a frequency spectrum, of the sound waves 14 acquired by structure-borne sound sensor 16 from the received signal from structure-borne sound sensor 16 . This can be performed with the aid of a frequency analysis in evaluation unit 25 , for example using a fast Fourier transformation FFT. The at least one determined frequency, or frequency spectrum, from acquired sound waves 14 is then forwarded by evaluation unit 25 to comparator unit 20 . Comparator unit 20 then checks whether the at least one frequency corresponds to a prespecified frequency from threshold value storage device 35 , and whether this frequency portion is situated above a threshold that is also stored in threshold value storage device 35 . In this case, an erroneous opening is also recognized of the at least one intake valve 3 1 S and/or of the at least one exhaust valve 4 , and error signal F is set. The prespecified frequency, or plurality of prespecified frequencies, with which the at least one frequency, determined by evaluation unit 25 , of the signal of structure-borne sound sensor 16 is compared can be determined for example on a test bench as characteristic for the escape of combusted exhaust gas 5 from combustion chamber 10 , caused for example by the erroneous opening of the at least one intake valve 3 and/or the erroneous opening of the at least one exhaust valve 4 . The same holds correspondingly for the determination of the prespecified threshold value that must be exceeded by the at least one frequency portion, determined by evaluation unit 25 , of the signal of structure-borne sound sensor 16 in order to recognize an erroneous opening of the at least one intake valve 3 and/or an erroneous opening of the at least one exhaust valve 4 as the cause of error.
[0030] In general, evaluation unit 25 can determine the frequency spectrum of the signal of structure-borne sound sensor 16 in the described manner, and comparator unit 20 then checks, on the basis of the frequency spectrum of the signal of structure-borne sound sensor 16 received by evaluation unit 25 , whether this frequency spectrum has at least one prespecified frequency portion having a magnitude that is greater than a prespecified threshold, in which case error signal F is set. The prespecified frequency portion and the prespecified threshold can be determined in the same way as the previously described frequency and its threshold value, for example on a test bench. Here it can also be provided that for the error recognition it is checked in comparator unit 20 whether the frequency spectrum has not just one but rather a plurality of frequency portions of sound waves 14 that are characteristic for the erroneous opening of the at least one intake valve 3 and/or of the at least one exhaust valve 4 and that are greater than a threshold value that is allocated to the respective frequency portion and that is likewise characteristic for the erroneous opening of the at least one intake valve 3 and/or of the at least one exhaust valve 4 ; these frequency portions and their allocated threshold values can also be applied in the described manner, for example on a test bench.
[0031] In the evaluation of the previously described amplitudes of the acquired sound waves, or the sound pressure level, sound intensity, or sound power thereof, the respectively allocated threshold value that is to be exceeded in order for an error to be recognized can also be applied for example on a test bench in such a way that its exceeding is characteristic for the exit of combusted exhaust gas 5 from combustion chamber 10 due to the erroneous opening of the at least one intake valve 3 and/or due to the erroneous opening of the at least one exhaust valve 4 , but that this exceeding cannot take place in the absence of such an error.
[0032] Finally, FIG. 4 shows a sequence diagram for an exemplary method according to the present invention. After the start of the program, at program point 100 request unit 40 produces a changeover request for the activation of the second operating state, beginning from the first operating state, by generating request signal A. Branching then takes place to a program point 105 .
[0033] At program point 105 , time element 30 is started. Branching then takes place to a program point 110 .
[0034] At program point 110 , evaluation unit 25 evaluates the signal of structure-borne sound sensor 16 with respect to one or more of the named quantities. Branching then takes place to a program point 115 .
[0035] At program point 115 , comparator unit 20 checks whether the evaluated quantity exceeds its allocated threshold value, or, in the case of a plurality of evaluated quantities, whether all the quantities each exceed their respectively allocated threshold value; in the case of frequency evaluation at program point 115 it is checked whether the frequency or frequency spectrum determined by evaluation unit 25 contains the prespecified frequency portion or portions each greater than the prespecified threshold value allocated to them. If this is the case, branching takes place to a program point 120 ; otherwise, branching takes place to a program point 125 .
[0036] At program point 120 , error signal F is set. Subsequently the program is exited.
[0037] At program point 125 , comparator unit 20 checks whether it is still receiving the release signal from time element 30 . If this is the case, branching takes place back to program point 110 ; otherwise, the program is exited.
[0038] The abrupt escape of combusted exhaust gas 5 from combustion chamber 10 in the case of an incorrectly opened intake valve 3 and/or an incorrectly opened exhaust valve 4 produces sound waves 14 in the described manner, and these sound waves are superposed on the sound waves produced during operation up to that point of the internal combustion engine, so that the resulting sound waves received by structure-borne sound sensor 16 are subject to a significant alteration with respect to the quantity or quantities evaluated by evaluation unit 25 , due to the sound waves 14 formed by the exhaust gas 5 escaping in abrupt fashion from combustion chamber 10 , and this alteration is acquired in the described manner with the aid of the prespecified frequency or frequency portions or the prespecified threshold values in threshold value storage device 35 , and is used for the recognition of the erroneous opening of the at least one intake valve 3 and/or of the at least one exhaust valve 4 .
[0039] If the operation of all exhaust valves of cylinder 2 is known to be error-free, the set error signal F can be allocated unambiguously to an erroneous opening of the at least one intake valve 3 . If the operation of all intake valves of cylinder 2 is known to be error-free, the set error signal F can be allocated unambiguously to an erroneous opening of the at least one exhaust valve 4 .
[0040] For the evaluation, the sound waves received by structure-borne sound sensor 16 may be allocated temporally to the opening, expected to be erroneous, of the at least one intake valve 3 and/or of the at least one exhaust valve 4 . Upon activation of the second operating state, beginning from the first operating state, the at least one intake valve 3 and/or the at least one exhaust valve 4 open in erroneous fashion at a predictable crank angle or at a predictable time. The sound waves that are thereby produced propagate, and are expected by structure-borne sound sensor 16 in the case of error. This temporal allocation also permits identification of the cylinder or cylinders that have the at least one incorrectly opening intake valve 3 and/or at least one incorrectly opening exhaust valve 4 . This is because, due to the ignition sequence known in engine control unit 18 for the individual cylinders, erroneous opening of an intake and/or an exhaust valve is expected at different times or crank angles.
[0041] Due to the temporal allocation, the sound waves received by structure-borne sound sensor 16 can also be distinguished with regard to whether they are caused by the erroneous opening of an intake valve or exhaust valve, or due to other causes, such as for example knocking combustion. | A method and a device for the diagnosis of at least one gas exchange valve of at least one cylinder of an internal combustion engine that is on the one hand reliable and on the other hand does without additional sensor equipment are described. In a first operating state of the internal combustion engine, at least one gas exchange valve of the at least one cylinder is activated. In a second operating state of the internal combustion engine, all the gas exchange valves of the at least one cylinder are deactivated and therewith closed in stationary fashion. Sound waves produced by the internal combustion engine are acquired. It is checked whether a significant change occurs in a quantity characterizing the acquired sound waves upon a transition from the first operating state to the second operating state. In this case, an erroneous opening of the at least one gas exchange valve is recognized. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. patent application Ser. No. 10/735,065, filed Dec. 12, 2003 now U.S. Pat. No. 6,950,510 and entitled “Routing Data Based On Comparative Income Values”, which is a continuation of U.S. patent application Ser. No. 09/749,970, filed Dec. 28, 2000 now U.S. Pat. No. 6,683,945 and entitled “Routing Data Based On Comparative Income Values”, each of which is hereby incorporated by reference in its entirety.
FIELD OF THE INVENTION
The present invention relates generally to routing data between first and second locations based on a comparative income value calculated for each of a plurality of available routings. More particularly, the present invention relates to routing the data based on which routing will generate the most income to the routing entity or which routing will result in the least expense to the routing entity.
BACKGROUND OF THE INVENTION
In recent years, a number of new telephone service features have been provided by an Advanced Intelligent Network (AIN). The AIN evolved out of a need to increase the capabilities of the telephone network architecture in order to meet the growing needs of telephone customers or users. Additionally, as the number of people who rely on the Internet for communication increases, so does the demand for the electronic transfer of data.
Referring now to FIG. 1 , it is seen that an AIN-based network arrangement is provided within and/or in conjunction with a telephone system LATA (Local Access and Transport Area) 101 that defines a calling service area. The LATA 101 includes stations (i.e. telephone lines and telephone equipment at the ends thereof) 103 and corresponding service switching points (SSPs) 105 (i.e., end offices or central offices). The SSPs 105 are each programmable switches which: recognize AIN-type calls; launch queries to service control points (SCPs) 107 (only one being shown in FIG. 1 ); and receive commands and data from SCPs 107 to further process and route AIN-type calls. A signal transfer point (STP) 109 may be employed to route signals between the SSPs 105 , the SCPs 107 , and other network elements. When one of the SSPs 105 is triggered by an AIN-type call, the triggered SSP 105 formulates an AIN service request and responds to call processing instructions from the network element in which the AIN service logic resides, typically at an SCP 107 .
In a telephone system such as those in LATA 101 , and absent other considerations, each SSP 105 routes a call from a station 103 coupled thereto and at a first location to a second location according to a generally static routing table that is included with or locally available to such SSP 105 (not shown). As may be appreciated, the second location may be any location, including a location within the LATA 101 , external to the LATA 101 but relatively local, or external to the LATA 101 and not relatively local, e.g.
However, and importantly, the information in a static routing table can quickly become old or ‘stale’. That is, such information is typically selected to optimize one or more parameters and is based on the telephone or data network within which calls/data are to be routed, and yet such telephone or data network can be expected to change on a minute by minute or even second by second basis. For example, a particular routing may go down at any time, or the operator of such routing may increase a usage cost rate at any time. In contrast with such a dynamic environment, the static routing table typically, is updated once every 24 hours or so. Therefore, the information that the routing table contains and uses to route calls/data quickly becomes obsolete. As is to be appreciated, usage of such obsolete information quickly becomes inefficient and costly.
Accordingly, a need exists for a cost effective method of routing calls/data between a first location and a second location using current real time information. In particular, a need exists for a method of routing calls/data that generates maximum revenue or that incurs the least cost to the routing entity.
SUMMARY OF THE INVENTION
The present invention satisfies the aforementioned need by providing a method of selecting routing of communications in a network with a plurality of paths between a first location and a second location. In the method, a routing choice is determined from among the plurality of paths based at least in part upon at least one of a communication-success amount of monetary relevance for each of the plurality of paths and a communication-failure amount of monetary relevance for each of the plurality of paths, and further upon at least one of a likelihood of successfully completing communication for each of the plurality of paths and a likelihood of failing to complete communication for each of the plurality of paths. At least one routing device is informed of the determined routing choice, whereby the routing device can select routing information for routing the data between the first location and the second location based on the determined routing choice.
BRIEF DESCRIPTION OF THE FIGURES
The foregoing summary as well as the following detailed description of the invention will be better understood when read in conjunction with the appended drawings. For the purpose of the illustrating the invention, there are shown in the drawings embodiments which are presently preferred. As should be understood, however, the invention is not limited to the precise arrangements and instrumentalities shown. In the drawings:
FIG. 1 is a block diagram and shows an Advanced Intelligent Network (AIN) based system for implementing intelligent network management features, such as that which may be employed in connection with the present invention;
FIG. 2 illustrates a chart showing a routing table including information employed to make routing decisions in accordance with one embodiment of the present invention; and
FIG. 3 illustrates a method of dynamically routing data such as a telephone call between a first location and a second location in accordance with one embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
In the present invention, data is dynamically routed between a first location and a second location based on information available in a centralized routing table. The data is typically a telephone call originating from within a LATA 101 such as that shown in FIG. 1 or the like. The first location and second location can be anywhere within the LATA 101 or at another LATA communicatively coupled to the LATA 101 without departing from the spirit and scope of the invention. Typically, the telephone call is routed by way of a data path such as a trunk line, although it is to be appreciated that other types of data paths such as microwave links, satellite links, direct links, etc. may be employed without departing from the spirit and scope of the invention.
Although the present invention is disclosed in terms of a telephone call over a telephone network, it is nevertheless to be appreciated that the data may be any other data, such as computer-type data or the like, without departing from the spirit and scope of the present invention. Moreover, such data can be transmitted by way of a network other than a telephone-type network, again without departing from the spirit and scope of the present invention. For example, the network may be a computer-type network such as the Internet or a private computer network.
In a typical telephone network, a local carrier operating one or more LATAs 101 typically completes calls within or between its LATAs 101 by way of data paths owned or controlled by such local carrier. For instance, local carrier A operating one or more LATAs 101 in the Wilkes-Barre, Pa. area would route a call within the area by way of lines owned or controlled by such carrier A. However, in the case where the call originates within the Wilkes-Barre, Pa. area but is destined for an area outside such the Wilkes-Barre, Pa. area, carrier A may have to route the call at least partially by way of a data path that is not owned or controlled by carrier A. For instance, if the aforementioned call is destined for a telephone line in Boynton Beach, Fla., carrier A may have to route the call at least partially by way of a long distance data path such as a trunk line operated by a long distance carrier B. The actual mechanical details of routing calls are generally known or should be apparent to the relevant public and therefore need not be discussed herein in any detail. Accordingly, any appropriate method of performing routing of calls may be employed without departing from the spirit and scope of the present invention.
As discussed above, each SSP 105 operated by the local carrier A may be provided with a static routing table includes all information necessary for routing the call from Wilkes-Barre, Pa. to Boynton Beach, Fla. Such a routing table is known or should be apparent to the relevant public. Accordingly, further details of such static routing table are not provided herein. Note that static routing tables or the like are also employed by data routers to route data between first and second locations.
As also discussed above, the data in the static routing tables can quickly become stale. Moreover, continually updating the data in each and every one of the far-flung tables at each and every one of the far-flung SSPs 105 can quickly become an elaborate and perhaps unwieldy process. Accordingly, in one embodiment of the present invention, such data is centralized and stored in one or perhaps a small number of centralized locations. In particular, in one embodiment of the present invention, and as seen in FIG. 1 , the routing table 10 is stored at one or more SCPs 107 , for example at a database 104 or the like which is included in or coupled to or accessible by the SCP 107 .
Accordingly, to complete a call that requires routing information, an SSP 105 makes a request to an SCP 107 for such routing information, and then completes the call based on the routing information as received from the SCP 107 . As known, the request to the SCP 107 from the SSP 105 may be based on the tripping of an appropriate trigger at the SSP 105 when the call is being made. Requesting information from an SCP 107 by an SSP 105 is generally known or should be apparent to the relevant public and therefore need not be discussed herein in any detail. Moreover, any particular method of requesting the routing information from the SCP 107 may be employed without departing from the spirit and scope of the present invention. Note that even with the routing table 10 stored at the SCP 107 , each SSP 105 should nevertheless have a reasonably up-to-date backup routing table locally available in the event the SCP 107 is out of operation or unable to communicate with the SSP 105 .
In one embodiment of the present invention, the routing information in the routing table 10 includes routing information for routing a call from a first location to a second location by way of a plurality of data paths capable of providing a link between the first location and the second location. For example, for routing a call from Wilkes-Barre, Pa. to Boynton Beach, Fla., several different carriers B, C, etc. may have corresponding data paths (trunk lines, e.g.) available for effectuating the link/call. Moreover, one or more of the carriers may each have multiple alternative data paths available for effectuating the link. For example, and as seen in FIG. 2 , carrier B may have a single data path B 1 , while carrier C has three data paths C 1 , C 2 , C 3 .
Importantly, and as also seen in FIG. 2 , for each data path B 1 , C 1 , C 2 , C 3 , the local carrier A associates a comparative value therewith indicative of how preferential the data path is, where the comparative values for all data paths between the first and second locations may be compared to determine a preferred data path. Such comparative value may be derived in any appropriate manner without departing from the spirit and scope of the present invention. In one embodiment of the present invention, the comparative value for each data path is a function of both a revenue value associated with the data path and the likelihood the call will be successfully completed on the data path.
For each data path, the revenue value associated therewith preferably has monetary relevance to the local carrier A. For example, if the use of the data path requires an overall outlay by carrier A, then the revenue value may represent an overall cost to carrier A, perhaps expressed in an appropriate per unit basis such as per unit of time (minute, e.g.). Here, overall cost may require a consideration of cost paid to owner/controller of the data path and also of value charged to the customer for making the call to result in a net cost per unit.
Similarly, if the use of the data path results in an overall income to the carrier A, then the revenue value may represent an overall income to carrier A, again perhaps expressed in an appropriate per unit basis such as per unit of time (minute, e.g.). Here, and also again, overall income may require a consideration of cost paid to the customer by the owner/controller of the data path directly and also of value charged to the customer for making the call to result in a net profit per unit. Deriving a revenue value for each data path is generally known or should be apparent to the relevant public and therefore need not be discussed in detail herein. Generally, any appropriate mechanism for deriving a revenue value for each data path may be employed without departing from the spirit and scope of the present invention.
As seen in FIG. 2 , for carrier A, each of data paths B 1 , C 1 , C 2 , C 3 between Wilkes-Barre, Pa. and Boynton Beach, Fla. has a revenue value of 0.10, 0.20, 0.50, and 0.90 dollars per minute, respectively. For purposes of the present example, the revenue value is representative of net profit to carrier A.
For each data path, the likelihood value associated therewith preferably relates to how often a call routed by carrier A through the data path is successfully completed. For example, suppose data path B 1 successfully completes the data link nine times out of every ten attempted linkages. Data path B 1 therefore has a 90% likelihood that a call attempted therethrough will be completed In one embodiment of the present invention, then, the likelihood value for each data path is an attempt success ratio (ASR) representative of a proportion of successful linkages by the data path to all attempted linkages by the data path. Deriving an ASR for each data path is generally known or should be apparent to the relevant public and therefore need not be discussed in detail herein. Generally, any appropriate mechanism for deriving an ASR for each data path may be employed without departing from the spirit and scope of the present invention.
As seen in FIG. 2 , for carrier A, each of data paths B 1 , C 1 , C 2 , C 3 between Wilkes-Barre, Pa. and Boynton Beach, Fla. has an ASR of 90, 70, 20, and 10 percent, respectively.
Now, a question arises regarding why the ASR for each data path is even considered. After all, if carrier A simply chooses to route the call by way of data path C 3 , such carrier A stands to gain a net profit of 0.90 dollars per minute, which is far better than 0.10, 0.20, or 0.50 dollars per minute based on data paths B 1 , C 1 , and C 2 , respectively. However, and importantly, carrier A gains such 0.90 dollars per minute net profit only if the call is successfully completed by way of data path C 3 . Moreover, the ASR for data path C 3 is only 10 percent, meaning that the call will likely be successfully completed only 1 time in 10.
Accordingly, on an overall basis, carrier A will gain 0.90 dollars per minute 10 percent of the time, or 0.09 dollars per minute on an overall basis. In one embodiment of the present invention, then, the comparative value for each data path is the revenue value associated with the data path multiplied by the ASR for the path. Also, in such embodiment, the highest comparative value (in a net profit scenario) or lowest comparative value (in a net cost scenario) of a plurality of data paths capable of providing a data link between a first location and a second location represents the best routing choice.
As seen in FIG. 2 , for carrier A, each of data paths B 1 , C 1 , C 2 , C 3 between Wilkes-Barre, Pa. and Boynton Beach, Fla. has a comparative value of 0.09, 0.14, 0.10 and 0.09 dollars per minute, respectively. Thus, data path C 1 as provided by carrier C is the best routing choice, data path C 2 as provided by carrier C is the second best routing choice, and data path B 1 and C 3 as provided by carriers B and C, respectively, tie for the third best routing choice. Of particular interest here is that even though data path C 1 has a revenue value of 0.20 dollars per minute, which is much less that the revenue value of 0.90 dollars per minute for data path C 3 , data path C 1 is nevertheless preferred over data path C 3 because the ASR of 70 percent for data path C 1 is so much higher than the ASR of 10 percent for data path C 3 .
Note that with regard to data path C 3 , for example, during the 9 times out of 10 that the call fails to complete, carrier A will incur set up costs for attempting to complete the call by way of such data path C 3 , and will otherwise tie up resources while the call waits to go through. Although the comparative value of the present invention does not take such set up costs and tied up resources into account, the relevant public should appreciate that the highest comparative value (in a net profit scenario) or lowest comparative value (in a net cost scenario) nevertheless represents the best routing choice.
In one embodiment of the present invention, then, and referring now to FIG. 3 , upon an SCP 107 receiving a request for routing information for a data link from an SSP 105 , the SCP 107 obtains a revenue value for each of a plurality of data paths capable of providing a data link between the first location and the second location (step 301 ), and also obtains an attempt success ratio (ASR) for each of the plurality of data paths (step 303 ). Thereafter, the SCP 107 computes a comparative value for each of the plurality of data paths, where the comparative value is the product of the attempt success ratio for the data path and the revenue value for the data path (step 305 ).
Based on the comparative values, then, the SCP 107 selects a best routing choice for the data link based on the comparative value for each data path, and the corresponding routing information for routing the data between the first location and the second location based on the best routing choice (step 307 ). Such routing information is then returned to the requesting SSP 105 (step 309 ), and such SSP 105 may then employ the returned routing information to route the telephone call by way of at least one of the data paths (step 311 ).
In one embodiment of the present invention, the SCP 107 selects at step 307 a plurality of best routing choices and therefore a corresponding plurality of data paths and a corresponding plurality of routing informations based on the comparative income values for the data paths. That is, rather than just selecting data path Cl based on its being the best routing choice, data path C 2 may also be selected based on its being the second best routing choice. Of course, additional data paths may also be selected without departing from the spirit and scope of the present invention. As may be appreciated, then all of the routing informations for all of the selected data paths are then returned at step 309 to the requesting SSP 105 , and the SSP 105 can then employ at step 311 any of the returned routing informations. Typically, one set of routing information represents a preferred set and another represents an alternate set. Accordingly, the SSP 105 may employ the preferred set to route the call, and if that fails the SSP 105 may employ the alternate set to route the call.
As set forth above, the comparative value for a data path is a function of the revenue value for the data path and the ASR for the data path. However, the comparative value for a data path may be a function of additional values without departing from the spirit and scope of the present invention. For example, values representing current switch conditions, current network conditions, available resources, time of day, and the like may be incorporated into a determination of the comparative value for each data path.
In one embodiment of the present invention, the revenue value and ASR for each data path as noted in the table 10 is updated on a regular basis with current data. The periodicity of such updates is preferably selected to avoid allowing such information to become stale. Particularly with regard to the ASR, this may require that updates be performed in a period of hours or even minutes, or perhaps even seconds. By updating on what amounts to a real-time or near real-time basis, the use of the most current revenue values and ASRs results in the computation of the most accurate comparative values and the most meaningful selection of routing information based on such comparative values.
In one embodiment of the present invention, and as seen in FIG. 1 , the table 10 receives such updates from one or more surveillance systems 12 . As may be appreciated, each surveillance system 12 continually monitors the telecommunications system and continually calculates current revenue values and current ASRs based on available system information. The surveillance systems 12 are generally known or should be apparent to the relevant public and therefore need not be discussed herein in any detail. Such systems 12 may be any appropriate systems without departing from the spirit and scope of the present invention.
As shown in FIG. 2 , the revenue value, ASR, comparative value, and routing information for each data path is stored in the routing table 10 at the SCP 107 . Nevertheless, at least some of such information may be stored at a location other than the routing table 10 without departing from the spirit and scope of the present invention. For example, it may be the case that only the routing information is in the routing table 10 , while the revenue value, ASR, and comparative value information is stored in another table at the SCP 107 . Further, it may be the case that the information of FIG. 2 is stored at an SSP 105 . Accordingly, the information may be stored in any appropriate manner and at any appropriate location(s) without departing from the spirit and scope of the present invention.
Note that with regard to the computing of the comparative value (step 305 ), such computation may be performed at any appropriate time and by any appropriate entity without departing from the spirit and scope of the present invention. For example, the computation may be performed by a loading entity as new revenue values and/or ASRs are loaded into table 10 or the like, and stored with such revenue values and ASRs in the table 10 or the like, or may be performed by an obtaining entity (the SCP 107 , e.g.) as revenue values and ASRs are obtained (step 301 , 303 ). In the latter case, the computed comparative values may be stored in the table 10 or the like, or it may be the case that the comparative values are not stored anywhere.
As should now be understood, in the present invention, data such as a telephone call is dynamically routed from a first location to a second location by way of one of a plurality of data paths based on a comparative value associated with each data path. Changes could be made to the embodiments disclosed above without departing from the broad inventive concepts thereof. It is understood, therefore, that this invention is not limited to the particular embodiments disclosed, but it is intended to cover modifications within the spirit and scope of the present invention as defined by the appended claims. | To select routing of communications in a network with a plurality of paths between a first location and a second location, a routing choice is determined from among the plurality of paths based at least in part upon at least one of a communication-success amount of monetary relevance for each of the plurality of paths and a communication-failure amount of monetary relevance for each of the plurality of paths, and further upon at least one of a likelihood of successfully completing communication for each of the plurality of paths and a likelihood of failing to complete communication for each of the plurality of paths. At least one routing device is informed of the determined routing choice, whereby the routing device can select routing information for routing the data between the first location and the second location based on the determined routing choice. | 7 |
This application claims the benefit of U.S. Provisional Application No. 60/801,566 and filed May 18, 2006.
FIELD OF THE INVENTION
The present invention relates to Michael addition adducts of vinylamines with various compounds having an unsaturated bond conjugated to an electron-withdrawing group, and a process for the production of vinylamine adducts. In particular, the present invention relates to Michael addition adducts of polyvinylamine with α,β-unsaturated alkyl carbonyl compounds including amides, esters and acids. Furthermore, the invention relates to uses of these adducts as, dry strength additives and/or retention/drainage aids for papermaking.
BACKGROUND OF THE INVENTION
Polyvinylamine has been used in many industrial and pharmaceutical applications. In the papermaking industry, polyvinylamine has been used as dry and/or wet strength additives as well as retention/drainage aids. Polyvinylamine has a linear backbone structure with no branches and possesses one primary amine group for every two carbon units. The polymer is highly cationic in an aqueous system with a broad pH range due to the high density of the primary amine. Thus, it has a strong hydrogen bonding ability, suitable for a variety of industrial applications.
Polyvinylamine has typically been made by free radical polymerization of N-vinylformamide monomer followed by a direct base- or acid-catalyzed hydrolysis by which the primary amine is deprotected and formic acid is released. A partially hydrolyzed and water-soluble homopolymer of N-vinylformamide that contains N-vinylformamide units and vinylamine units has also be prepared, as disclosed in U.S. Pat. No. 4,421,602. U.S. Pat. No. 2,721,140 discloses the use of polyvinylamine as an additive to make papers having high wet strength. U.S. Pat. No. 4,421,602 also disclosed the use of polyvinylamine and a 50% hydrolyzed polyvinylformamide to increase efficiencies of flocculation, retention of fines and drainage rate of pulp fiber in papermaking process. U.S. Pat. No. 5,961,782 discloses the use of polyvinylamine to make crosslinkable creping adhesive formulations. U.S. Pat. No. 6,159,340 disclosed the use in papermaking of polyvinylamine and a 50% hydrolyzed polyvinylformamide as dry and wet strength additives in paper and paperboard production. U.S. Pat. Nos. 6,616,807 and 6,797,785 disclose the use of polyvinylamine as drainage aids, flocculants and retention aids in the paper industry. Despite its unique properties and wide applications of polyvinylamine and its derivatives, other polyvinylamine alternatives are still being sought.
As disclosed in U.S. Pat. No. 4,774,285, N-vinylformamide monomer may be copolymerized with an additional vinyl monomer, e.g., vinyl acetate, followed by a subsequent hydrolysis to produce a water-soluble copolymer of vinylamine and vinyl alcohol. These water-soluble copolymers may be used as wet and dry strength additives for papermaking. Further, U.S. Pat. No. 5,630,907 disclosed copolymer compositions containing vinylamine units and acrylic acid units, and their applications. U.S. Pat. No. 6,797,785 disclosed copolymer compositions containing vinylamine units and diallyldimethylammonium (chloride) (“DADMAC”) units or acrylamide units via reverse emulsion polymerization, and the uses of those copolymers as flocculants and coagulants for the papermaking industry. EP 0251182 disclosed a copolymer that contains vinylamine units and acrylonitrile units for use in papermaking as drainage, retention agents, and as a wet end additive to increase dry strength resin of paper products. In general, those copolymer compositions contain vinylamine units and an additional vinyl units linked together randomly through C—C bond in a linear fashion, and those compositions reduce the density of vinylamine units in the polymer backbone, thereby giving it a lower cationic charge density as compared to polyvinylamine.
The derivatization of polyvinylamine by modifying the primary amines is an alternative approach to produce polyvinylamine analogs with altered physical and application properties. For example, U.S. Pat. No. 5,292,441 disclosed the use of quaternized polyvinylamines as flocculants for wastewater clarification and the quaternized polyvinylamines are obtained from the reaction of a polyvinylamine with a quaternizing agent such as methyl chloride, dimethyl sulfate or benzyl chloride. U.S. Pat. No. 5,994,449 disclosed a resin composition that is a reaction product of epihalohydrin with a mixture of a poly(vinylamine-co-vinyl alcohol) copolymer and a polyaminoamide and use of this composition as a creping adhesive.
The present invention is directed to modification of polyvinylamine through a Michael addition reaction. Michael addition is a chemical reaction that involves a conjugate addition of a nucleophile to an α,β-unsaturated bond conjugated to an electron-withdrawing group, particularly α,β-unsaturated carbonyl compounds resulting in a chain-extended product. One interesting advantage of this addition reaction is that there are no by-products released by the reaction. As a result, the Michael addition reaction has been widely used in organic synthesis and also applied to polymer chemistry on many occasions.
SUMMARY OF THE INVENTION
This invention relates to a Michael addition product of vinylamine, such as a vinylamine homopolymer (polyvinylamine), a vinylamine copolymer or a vinylamine terpolymer with a compound that has an α,β-unsaturated bond conjugated to an electron withdrawing group, particularly with an α,β-unsaturated alkyl carbonyl compound. In this composition, the unsaturated alkyl carbonyl compound is appended onto the vinylamine backbone through a nucleophilic addition of the primary amines of vinylamine, preferably polyvinylamine to the unsaturated moiety to form N—C linkages, wherein the unsaturated double bond subsequently becomes saturated.
Generally the invention relates to a Michael addition adduct having the general formula:
wherein
X 1 is selected from the group consisting of carboxyl, carboxamide, hydroxyl, alkylamine, alkanoxyl, alkenyl, alkyenyl, nitro and cyano groups and X 2 comprises any electron-withdrawing group or amine, R 1 and R 2 may be the same or different and are selected from the group consisting of H, alkyl, alkenyl, alkyenyl, carbonyl, carboxyl, and carboxamide groups, m, n and q are positive integers, representing numbers of its repeating unit distributed in the polymer in a random fashion, m+q ranges from 2,000 to 20,000, m/(m+q) ranges from 2/100 to 95/100 and n is a positive integer between 0 to 18,000. When n equals to 0, the polymer used for Michael addition is polyvinylamine homopolymer.
Specifically, acrylamide or dimethyl maleate is added to vinylamine by Michael addition at various molar ratios of the added compound to the vinylamine based on its repeating units. In the case of polyvinylamine, all the repeating units of polyvinylamine have small molecular weights at 43 with one primary amine. Adding one compound to each of the repeating units increases the total weight of polyvinylamine but has little effect on the physical size and molecular structure of the polymer in an aqueous medium. After the addition reaction, many, if not all, of the primary amines of polyvinylamine are converted to secondary amines depending on the molar ratio of the added compound to the repeating unit. When acrylamide is used, 3-alkylamino-propionamide functional groups are formed and branched out from the linear backbone of the polymer. The branched amide group changes the physical properties of polyvinylamine in aqueous medium and enhances intermolecular and intramolecular interactions, and reduces its binding ability to water. Chemically, the primary amine is converted to a secondary amine, which lowers the cationic charge density of the polymer. Practically, these changes in physical and chemical properties ultimately affect application properties, such as bonding affinity to pulp fiber, crosslinking ability, and interactions with other polymers etc.
Michael addition reaction of vinylamines is generally conducted in a reaction media, typically in water, at the solids content of the vinylamine at about 10-20%. The addition reaction is carried out under alkaline conditions where the amine is free and available for the reaction. The reaction is generally performed at an elevated temperature for about 2-5 hours without using any catalysts.
Michael addition adducts of vinylamine with acrylamide or dimethyl maleate, when used as papermaking additives, provide improved or equivalent dry strength relative to polyvinylamine to the paper products made using a paper machine. The materials are effective at the treatment level from about 0.01% to about 0.5% based on the dry pulp. The products also give good drainage and retention properties to the pulp fiber.
The compositions of the present invention, most broadly, can be made by adding a compound having an α,β-unsaturated bond conjugated to an electron-withdrawing group to the amine group of a vinylamine, such as a vinylamine homopolymer (polyvinylamine), a vinylamine copolymer or a vinylamine terpolymer, preferably a polyvinylamine. The composition comprises repeating units having a general formula in Formula A, wherein
R 1 and R 2 is H, any alkyl, alkenyl, alkyenyl, carbonyl, carboxyl, or carboxamide, Y is carbonyl, carboxyl, carboxamide, sulphonamide, sulphonimide, sulphonyl, or phosphonyl group, R 3 is H, OH, NH 2 , SH and any short chain (C 1 -C 5 ) and long chain (C 6 -C 22 ) alkyl group, Z is nitro, cyano, or other electron-withdrawing groups as known to the art, X 1 is as stated above, q and m represent the repeating units of vinylamine and the repeating units of the reacted vinylamine, respectively, and the total q+m or r is any number between about 2,000 to about 20,000, m/(m+q) is about 2/100 to about 95/100; n is a positive integer between 0 to 18,000. When n equals to 0, the polymer used for Michael addition is polyvinylamine homopolymer.
Most preferably, however, is the Michael adduct composition of polyvinylamine with a compound having a conjugated double bond conjugated to a carbonyl group, as indicated in general formula A wherein
R 1 is H, carboxylic acid, carboxylate methyl ester, R 2 is H, or methyl, Y is carboxamide or carbonyl, R 3 is H, NH 2 or OH, m+q, is any number between about 2000 to about 10,000 and m/(m+q) is about 1/20 to about 95/100; n is 0.
In a preferred group of compositions within the invention, acrylamide is used for the addition reaction. The molar ratio of acrylamide to the repeating vinylamine units is preferably greater than about 0.05 but less than about 1. When the molar ratio is about 1, all the primary amines of vinylamine become reacted with acrylamide. At least one repeating vinylamine unit reacts with acrylamide or another compound having -unsaturated group conjugated to an electron-withdrawing group to form the structure as indicated in the general formula A. More preferably, the molar ratio of acrylamide to the repeating vinylamine units in polyvinylamine is greater than about 0.2 to less than about 0.9. Most preferably, the molar ratio of acrylamide to the repeating unit is about 0.67 at which ratio the new composition provided the desired application property for the paperboard product.
Sometimes, it is desirable to react further the Michael addition adduct to produce polyvinylamine derivative with additional functionalities as shown in the following reaction scheme. As a representative example, the Michael addition adduct in Formula B, wherein R 1 is H or COOCH 3 , R 2 is H or methyl, and R 4 is OCH 3 or NH 2 , can be further hydrolyzed under acid or basic condition, partly or completely, to produce amphoteric polymer compositions as showed in the Formula B wherein R 1 is H or COOH, R 2 is H or methyl, and R 4 is OH.
Also, the Michael addition of polyvinylamine with a compound having a carboxamide group (e.g., acrylamide) can be converted to a new composition through a Hoffmann Rearrangement using sodium hyperhalide under alkaline conditions. The new polymer has a general formula in Formula C wherein R 1 is H or an alkyl group, R 2 is H or methyl, and Y is NH 2 . In this approach, additional primary amino groups are created and extended from the polyvinylamine backbone.
Furthermore, the Michael addition adduct of vinylamine with acrylamide can react with an aldehyde or a dialdehyde to produce a modified polyvinylamine with N-(1-substituted hydroxylmethylene) propionamide groups branched out from the amine groups. This type of novel polymers has a general formula in Formula D wherein R 3 is H or CHOHR 4 and R 4 is CHO or any alkyl group or substituted alkyl group, and R 2 is H or methyl. When a dialdehyde compound, such as glyoxal, is used, a reactive functional group is introduced to the Michael adduct of vinylamide with acrylamide. The glyoxalated Michael adduct may be used as a temporary wet strength material or an enhanced dry strength additive for papermaking uses.
Specifically, acrylamide or dimethyl maleate is added to vinylamine by Michael addition at various molar ratios of the added compound to the vinylamine based on its repeating units. In the case of polyvinylamine, all the repeating units of polyvinylamine have small molecular weights at 43 with one primary amine. Adding one compound to each of the repeating units increases the total weight of polyvinylamine but has little effect on the physical size and molecular structure of the polymer in an aqueous medium. After the addition reaction, many, if not all, of the primary amines of polyvinylamine are converted to secondary amines depending on the molar ratio of the added compound to the repeating unit. When acrylamide is used, 3-alkylamino-propionamide functional groups are formed and branched out from the linear backbone of the polymer. The branched amide group changes the physical properties of polyvinylamine in aqueous medium and enhances intermolecular and intramolecular interactions, and reduces its binding ability to water. Chemically, the primary amine is converted to a secondary amine, which lowers the cationic charge density of the polymer. Practically, these changes in physical and chemical properties ultimately affect application properties, such as bonding affinity to pulp fiber, crosslinking ability, and interactions with other polymers etc.
Michael addition reaction of vinylamines is generally conducted in a reaction media, typically in water, at the solids content of the vinylamine at about 10-20%. The addition reaction is carried out under alkaline conditions where the amine is free and available for the reaction. The reaction is generally performed at an elevated temperature for about 2-5 hours without using any catalysts.
Michael addition adducts of vinylamine with acrylamide or dimethyl maleate, when used as papermaking additives, provide improved or equivalent dry strength relative to polyvinylamine to the paper products made using a paper machine. The materials are effective at the treatment level from about 0.01% to about 0.5% based on the dry pulp. The products also give good drainage and retention properties to the pulp fiber.
DETAILED DESCRIPTION OF THE INVENTION
The compositions of the present invention, can be made by adding a compound having an α,β-unsaturated bond conjugated to an electron-withdrawing group to the amine group of a vinylamine, such as a vinylamine homopolymer (polyvinylamine), a vinylamine copolymer or a vinylamine terpolymer, preferably a polyvinylamine. The composition comprises repeating units having a general formula in Formula A, wherein
R 1 and R 2 is hydrogen or any alkyl, alkenyl, alkyenyl, carbonyl, carboxyl, or carboxamide, Y is carbonyl, carboxyl, carboxamide, sulphonamide, sulphonimide, sulphonyl, or phosphonyl group, R 3 is H, OH, NH 2 , SH and any short chain (C 1 -C 5 ) and long chain (C 6 -C 22 ) alkyl group, Z is nitro, cyano, or other electron-withdrawing groups as known to the art, m and n represents the repeating units of vinylamine and the repeating units of the reacted vinylamine, respectively, and the total n+m is any number between about 2,000 to about 20,000, n/(m+n) is about 2/100 to about 95/100.
Most preferable, however, is the Michael adduct composition of polyvinylamine with a compound having a conjugated double bond conjugated to a carbonyl group, as indicated in general formula A wherein
R 1 is H, carboxylic acid, carboxylate methyl ester, R 2 is H, or methyl, Y is carboxamide or carbonyl, R 3 is H, NH 2 or OH, m+n, is any number between about 2000 to about 10,000 and n/(m+n) is about 1/20 to about 95/100; x1 is as above; n is a m/m+
In a preferred group of compositions within the invention, acrylamide is used for the addition reaction. The molar ratio of acrylamide to the repeating vinylamine units is preferably greater than about 0.05 but less than about 1. When the molar ratio is about 1, all the primary amines of vinylamine become reacted with acrylamide. At least one repeating vinylamine unit reacts with acrylamide or another compound having α,β-unsaturated group conjugated to an electron-withdrawing group to form the structure as indicated in the general formula A. More preferably, the molar ratio of acrylamide to the repeating vinylamine units in polyvinylamine is greater than about 0.2 to less than about 0.9. Most preferably, the molar ratio of acrylamide to the repeating unit is about 0.67 at which ratio the new composition provided the desired application property for the paperboard product.
Sometimes, it is desirable to react further the Michael addition adduct to produce polyvinylamine derivative with additional functionalities as shown in the following reaction scheme. As a representative example, the Michael addition adduct in Formula B, wherein R 1 is H or COOCH 3 , R 2 is H or methyl, and R 4 is OCH 3 or NH 2 , can be further hydrolyzed under acid or basic condition, partly or completely, to produce amphoteric polymer compositions as showed in the Formula B wherein R 1 is H or COOH, R 2 is H or methyl, and R 4 is OH.
Also, the Michael addition of polyvinylamine with a compound having a carboxamide group (e.g., acrylamide) can be converted to a new composition through a Hoffmann Rearrangement using sodium hyperhalide under alkaline conditions. This polymer has a general formula shown in Formula C wherein R 1 is H or an alkyl group, R 2 is H or methyl, and Y is NH 2 . In this approach, additional primary amino groups are created and extended from the polyvinylamine backbone.
Furthermore, the Michael addition adduct of vinylamine with acrylamide can react with an aldehyde or a dialdehyde to produce a modified polyvinylamine with N-(1-substituted hydroxylmethylene) propionamide groups branched out from the amine groups. This type of novel polymers has a general formula in Formula D wherein R 3 is H or CHOHR 4 and R 4 is CHO or any alkyl group or substituted alkyl group, and R 2 is H or methyl. When a dialdehyde compound, such as glyoxal, is used, a reactive functional group is introduced to the Michael adduct of vinylamide with acrylamide. The glyoxalated Michael adduct may be used as a temporary wet strength material or an enhanced dry strength additive for papermaking uses.
The synthesis to produce the Michael addition adduct of vinylamine polymer with acrylamide for example is typically performed in water, however, it may also utilize an organic solvent or may be performed neat. The adduct products can be obtained with or without purification. In general, the acrylamide is added gradually to a vinylamine aqueous solution, preferably a polyvinylamine aqueous solution, at about 30° C. to about 50° C. at pH of about 9.0 to about 11.0 over about 20-30 minutes. After the addition, the reaction can be conducted in a pH, preferably, ranged from about 7 to about 14, more preferably at about 9.0 to about 12.0, and most preferably at about 11.0 to about 11.5, at a reaction temperature, preferably in the range of about 10° C. to about 90° C., more preferably at about 30° C. to about 80° C., and most preferably about 50° C. to about 70° C., for a time sufficient to complete reaction, generally about 15 minutes to about 12 hours, more preferably about 1 hour to about 8 hours, and most preferably about 3 to about 5 hours. The reaction can be enhanced at the elevated temperature. However, care must be taken to prevent acrylamide from being hydrolyzed to acrylic acid at a high temperature under strong alkaline conditions before it reacts with the amine. The double bond of acrylic acid has little reactivity to the amine nucleophile because ionization of the carboxylic acid under alkaline pH stabilizes the conjugated double bond.
In general, the molecular weight of vinylamine polymer has little effect on the reaction efficiency of Michael addition reaction. To produce the Michael addition adducts for papermaking uses, the molecular weight of vinylamine is preferably in the range of about 10,000 to about 1,000,000 Daltons, more preferably in the range of about 50,000 to about 500,000 Daltons, and most preferably in the range of about 200,000 to about 400,000 Daltons. The reaction is preferably performed at about 1% to about 50% solids in water, more preferably at about 5% to about 25%, and most preferably at about 10% to about 20%.
The molecular weight of Michael addition adducts of the present invention are important for their use in papermaking as strength additives. In a preferred group of compositions within the invention where acrylamide is used for the addition reaction, the molecular weight (M w ) of the product is preferably in the range of about 100,000 to about 1,000,000 Daltons, more preferably in the range of from about 200,000 to about 600,000 Daltons, and most preferably in the range of from about 250,000 to about 450,000 Daltons. In this preferable molecular weight range, the Michael addition adducts are low enough as not to bridge between molecules to cause flocculation of the adduct but high enough to retain on the pulp fibers.
Typically, the addition of acrylamide onto the primary amine of vinylamine is conducted in water with about 12% solids of the vinylamine. The viscosity of the product is reduced from about 2020 cps at about 12% solids to 460 cps at about 15% solids after the Michael addition. This significant decrease in viscosity is caused by the enhanced intermolecular and intramolecular interactions of the Michael adduct and therefore reduced water binding ability of the secondary amine, relative to the primary amine of the unreacted polyvinylamine. The composition of the adduct has been confirmed by 1 H— and 13 C-NMR analyses. 1 H-NMR spectrum of the final product displays two new and broad signals at 2.3 and 2.8 ppm, representing the saturated ethylene protons of N-propionamide. No proton signal is observed in the region of 5.5-6.5 ppm, suggesting that all the acrylamide has been covalently appended to the amine groups of the vinylamine polymer. 13 C-NMR analysis showed one single peak at 180 ppm, indicating a saturated amide carbon. Liquid chromatographic analysis of the acrylamide monomer shows 30-70 ppm of the residual acrylamide that can be completely decomposed by treating the final product with 1-5% sodium metabisulfite. At pH 7.0, the charge density of the Michael addition adduct is 4.7 meq/g while the unreacted vinylamine is at 10.0 meq/g at pH 7.0. The result also suggests that the primary amines in vinylamine have been modified.
Brookfield viscosity (BV) is measured using a DV-II Viscometer (Brookfield Viscosity Lab, Middleboro, Mass.). A selected spindle (number 27) is attached to the instrument, which is set for a speed of 30 RPM. The reaction solution is prepared at a certain solid content. The Brookfield viscosity spindle is carefully inserted to the solution so as not to trap any air bubbles and then rotated at the above-mentioned speed for 3 minutes at 24° C. The units are centipoises.
In order to obtain a molecular weight measurement of the Michael addition adducts described herein gel permeation chromatography was used. The analysis was accomplished by the use of gel permeation columns (CATSEC 4000+1000+300+100) using Waters 515 series chromatographic equipment with a mixture of solution (1% NaNO3/0.1% trifluoroacetic acid in 50:50 H2O:acetonitrile) as the mobile phase with a flow rate at 1.0 ml/min. The detector was a Hewlett Packard 1047A differential refractometer. The column temperature is set at 40° C. and the detector temperature is at 35° C. The molecular weight average was calculated against commercial and narrow mw standard poly(2-vinyl pyridine). Estimates of the number average (Mn) and weight average molecular weight (Mw) of the product mixtures were then computer-generated.
The Michael addition adducts of vinylamine can be produced with a wide range of compounds having unsaturated bond conjugated to an electron-withdrawing group. Examples of the suitable and preferred compounds contemplated include, but are not limited to, acrylamide, N-alkylacrylamide, methacrylamide, N-alkylmethacrylamide, N-(2-methylpropanesulfonic acid)acrylamide, N-(glycolic acid)acrylamide, N-[3-(propyl)trimethylammonium chloride]acrylamide, acrylonitrile, acrolein, methyl acrylate, alkyl acrylate, methyl methacrylate, alkyl methacrylate, aryl acrylate, aryl methacrylates, [2-(methacryloyloxy)ethyl]-trimethylammonium chloride, N-[3-(dimethylamino)propyl]methacrylamide, N-ethylacrylamide, 2-hydroxyethyl acrylate, 3-sulfopropyl acrylate, 2-hydroxyethyl methacrylate, glycidyl methacrylate, pentafluorophenyl acrylate, ethylene diacrylate, ethylene dimethacrylate heptafluorobuty-I acrylate, poly(methyl methacrylate), acryloylmorpholine, 3-(acryloyloxy)-2-hydroxyypropyl methacrylate, dialkyl maleate, dialkyl itaconate, dialkyl fumarate, 2-cyanoethyl acrylate, carboxyethyl acrylate, phenylthioethyl acrylate, 1-adamantyl methacrylate, dimethylaminoneopentyl acrylate, 2-(4-benzoyl-3-hydroxyphenoxy)ethyl acrylate, and dimethylaminoethyl methacrylate.
The Michael addition adducts described herein can be used in numerous applications depending on the nature of the electron withdrawing group of the added compounds. Adducts made with acrylamide can be used as dry or wet strength resin because the additional amide groups enhance inter- or intra-molecular interactions. The amide group added can be further hydrolyzed to a carboxylic acid or converted to a primary amide via Hoffmann Rearrangement. Adducts which contain carboxylic acids, obtained through hydrolysis of the propionamide groups, have amphoteric structures and can also be used, for example, as strength additives or retention and drainage aids in papermaking industry, and as flocculants for water treatment. Adducts which contain ethylamine groups, obtained through Hoffmann Rearrangement can also be used as strength additives, retention/drainage aids, and coagulants in water treatment and many other similar industrial applications.
A difunctional or multi-functional α,β-unsaturated carbonyl compound can be used to crosslink vinylamine through a Michael addition reaction. The examples of those difunctional or multi-functional compounds are: ethylene glycol diacrylate, methylenebisacrylamide, 1,4-butanediol diacrylate, bisphenol diacrylate, polyethylene glycol diacrylate, hexanediol diacrylate, 1,10-decanediol diacrylate, dicyclopentenyl acrylate, dicyclopentenyl methacrylate, carboxyethyl acrylate, polyethoxy methacrylatemethacrylate, phenylthioethyl acrylate, 1-adamantyl methacrylate, dimethylaminoneopentyl acrylate, 2-(4-benzoyl-3-hydroxyphenoxy)ethyl acrylate, dimethylaminoethyl methacrylate, polyfunctional acrylamide, polyfunctional acrylates, polyfunctional methacrylates, polyfunctional maleates, and polyfunctional fumarates. The crosslinked adducts can be used as strength additive, retention aid in papermaking, or as adhesive for construction uses, plasticizers or modifiers for optimizing resin properties.
N-(Long chain alkyl)acrylamide or any α,β-unsaturated carbonyl compound having a hydrophobic functional group can be added to vinylamine through Michael addition to produce a hydrophobically modified vinylamine derivative. The hydrophobic adducts can be used as retention aids, deposit control agents in papermaking process, flocculants in wastewater treatment, plasticizers, viscosifiers, and coating materials for various industrial applications.
Above mentioned compounds containing α,βunsaturated alkyl carbonyl groups can be also added to the primary amine of a copolymer or terpolymer of vinylamine with other monomers through Michael addition. Other primary amine-containing polymers such as polyethylenimine (PEI) can also be applied to the Michael addition reaction disclosed in this invention using the above mentioned compounds with α,β-unsaturated alkyl carbonyl groups.
In a preferred group of compositions, the Michael addition adducts of polyvinylamine with acrylamide and/or dimethyl maleate are used as dry strength additive for paper products and to accelerate drainage of the pulp fiber and to increase the retention of fines and fillers by the pulp fibers during the papermaking process.
It is preferable that the Michael addition adducts of the present invention contain at least 2% (on molar basis) unreacted primary amine remained on the polymer backbone so as to be effective cationic polymers for various applications including papermaking uses. While not wishing to be bound by theory, it is believed that the unreacted primary amines distributed evenly along the polymer backbone, balance the secondary amine formed by the Michael addition reaction thereby providing effective interactions with pulp fibers through multiply hydrogen bond and charge interactions
The embodiments of the invention are defined in the following Examples. It should be understood that these Examples are given by way of illustration only. Thus various modifications of the present invention in addition to those shown and described herein will be apparent to those skilled in the art from the foregoing description. Although the invention has been described with reference to particular means, materials and embodiments, it is to be understood that the invention is not limited to the particulars disclosed, and extends to all equivalents within the scope of the appended claims. In the following Examples, all parts and percentages are by weight, unless otherwise indicated.
EXAMPLES
Example 1
Polyvinylamine Acrylamide Michael Addition Adduct
A polyvinylamine solution (Hercobond® 6363 dry strength resin, 1000 g, 12% active solids, available from Hercules Incorporated) was added to a 2 L-reaction flask and was adjusted to pH 11.3-11.5 using 50% NaOH. Acrylamide solution (160 g, 50%) was added dropwise at room temperature for 20 minutes while the temperature of the reactants gradually increased to 40-45° C. The resulting mixture was stirred at 70° C. for 5 hours and the pH of the reaction mixture was maintained at 11.0-11.5 using 50% NaOH. The reaction mixture was then cooled down to 25-30° C. and the pH was adjusted to 8.0-9.0 using a concentrated HCl. To the resulting solution was added sodium metabisulfite (1 g). The mixture was stirred for 10 minutes at room temperature. The resultant product had 15.2% solids, pH 8.5, 460 cps Brookfield viscosity. The residual acrylamide was not detected by a standard liquid chromatographic method specifically designed for monomer analysis. The charge density of the polymer was measured to be 4.7 meq/g (pH 7.0). The structure was confirmed with 1 H and 13 C-NMR analysis and the molar ratio of vinylamine units to the added acrylamide was determined to be 60 to 40 based on the integration of 1 H-NMR. 1 H-NMR (D 2 O, 300 Hz) ppm 2.50-3.10 (broad, 3HX1.2, —CH—N— and —N—CH2-C—CON—), 2.20-2.40 (broad, 2HX0.66, C—N—C—CH2-CON—), 1.20-1.85 (broad, 2H, backbone methylene —CH2-); 13C-NMR (D2O, 75.5 Hz): ppm 180 (—CONH—), 55 (backbone —C—NH—), 48 (backbone —C—NH2), 44 (backbone methylene), 37 (ethylene of N-propionamide).
Example 2
Amphoteric Polyvinylamine Propionic Acid Using Acrylamide
A polyvinylamine solution (Hercobond® 6363 dry strength resin, 500 g, 12% active solids, available from Hercules Incorporated) was added to a 1 L-reaction flask and adjusted to pH 11.3-11.5 using 50% NaOH. Acrylamide solution (80 g, 50%) was added dropwise at room temperature for 20 minutes while the temperature of the reactants gradually increased to 40° C. The resulting mixture was stirred at 70° C. for 5 hours and the pH of the reaction mixture was maintained at 11.0-11.5 using 50% NaOH. To the reactants was added NaOH solution (50%, 9 g). The resulting mixture was stirred at 75° C. for 3 hours and water was added to reduce viscosity of the materials at different times. The material was then cooled down to 25-30° C. and the pH was adjusted to 8.0-9.0 using concentrated HCl. The product had 12.2% solids. The structure was confirmed by 13C-NMR analysis and the ratio of the vinylamine units in polyvinylamine, acrylamide and acrylic acid to be 60:32:8. 13C-NMR (D2O, 75.5 Hz): the integrated ratio of ppm 180 (—CONH—) and ppm 183 (—COOH—) equals to 4:1.
Example 3
Michael Addition Adduct of Polyvinylamine Using Dimethyl Maleate and Acrylamide
A polyvinylamine solution (Hercobond® 6363 dry strength resin, 500 g, 12% active solids, available from Hercules Incorporated) was added to a 1 L-reaction flask and adjusted to pH 9.5 using 50% NaOH. Dimethyl maleate (11 g) was added dropwise at room temperature in 10 minutes followed by the addition of acrylamide (50%, 76 g). The resulting mixture was stirred at 24° C. for 1 hour and the pH of the reaction mixture was adjusted to 11.2-11.5 by adding 25 g 50% NaOH. The resulting mixture was stirred at 50° C. for 3 hours and 70° C. for 2 hours and water was added to reduce viscosity of the materials at different times. After cooling down, the pH was adjusted to 9.0 to give the product having 12.3% solids. The ratio of the vinylamine unit in polyvinylamine, maleic acid and acrylamide was determined to be 50:15:35.
Example 4
Michael Addition Adduct of Polyvinylamine Using Dimethyl Maleate and Acrylamide
A polyvinylamine solution (Hercobond® 6363, 500 g, 12% active solids) was added to a 1 L-reaction flask and adjusted to pH 9.5 using 50% NaOH. Dimethyl maleate (30 g) was added dropwise at room temperature in 10 minutes followed by the addition of acrylamide (50%, 60 g). The resulting mixture was stirred at 24° C. for 1 hour and the pH of the reaction mixture was adjusted to 11.2-11.5 by adding 25 g 50% NaOH. The resulting mixture was stirred at 50° C. for 3 hours and 70° C. for 2 hours and water was added to reduce viscosity of the materials at different times. After cooling down, the pH was adjusted to 9.0 to give the product having 5.5% solids. The ratio of the vinylamine unit in polyvinylamine, maleic acid and acrylamide was determined to be 50:25:25.
Example 5
Michael Addition Adduct of Polyvinylamine with Methyl Acrylate and a Hydrolyzed Product
A polyvinylamine solution (Hercobond® 6363 dry strength resin, 100 g, 12% active solids, available from Hercules Incorporated) was added to a 250 ml-reaction flask is adjusted to pH 9.5 using 50% NaOH. Methyl acrylate (6 g) was added dropwise at room temperature in 20 minutes while the pH was maintained at 9.0-9.5. The resulting mixture was stirred at 24° C., pH 9.5 for 2 hour and the pH of the reaction mixture was adjusted to 11.0 using the 50% NaOH solution. The resulting mixture was stirred at 50° C. for 3 hours. After cooling down, the pH was adjusted to 9.0.
Example 6
Chemical and Physical Properties of the Adducts
The four Michael addition adducts were synthesized as described in Examples 1-4. In the first three cases (see Table I below), viscosities of the adducts decrease as compared to the starting polyvinylamine. However, the adduct's viscosity in Example 4 was the only one that increases. The viscosities remain substantially unchanged after 30 days at pH of about 8 to 11. The charge densities of the adducts decrease and varies with the added functional group and depending on whether the product was amphoteric or cationic. The residual acrylamide of the adducts was 30-70 ppm but was undetected after treating the final product with 1% N 2 S 2 O 5 .
TABLE I
Chemical and Physical Properties of the Adducts
Structure based
Charge
Residual
on
Chemical
BV (5%)
density
Acrylamide
Formula A
composition
(cPs)
(pH = 7)
(ppm)
Example 1
R 1 , R 2 ═H,
cationic
22
4.7
32
X═CONH 2
Example 2
R 1 , R 2 ═H,
amphoteric
22
2.6
97
X═COOH or CONH2
Example 3
R 1 ═COOH or H, R 2 ═H,
amphoteric
43
2.2
78
X═COOH or CONH 2
Example 4
R 1 ═COOH or H, R 2 ═H,
amphoteric
156
−0.48
143
X═COOH or CONH 2
Hercobond ® 6363
cationic
70
8.2
None
Example 7
Evaluations for Papermaking Application
Dry strengths of papers made from the Michael addition adducts of polyvinylamine prepared in above examples were compared with dry strengths of paper made with benchmark products Hercobond® 6363 dry strength resin(polyvinylamine), available from Hercules Incorporated and Hercobond® 6350 dry strength resin(a homopolymer of N-vinylformamide containing 50% N-vinylformamide and 50% polyvinylamine, available from Hercules Incorporated). Furthermore, the dry strengths were compared to papers with no strength additive (blank).
The linerboard paper was made using a papermaking machine. The paper pulp was a 100% recycled medium, JSSC/JAX, with 50 ppm hardness, 25 ppm alkalinity, 2.5% GPC D15F and 1996 uS/cm conductivity. The system pH was 7.0 and the pulp freeness was 351 CSF with the stock temperature at 52° C. The basis weight was 100 lbs/ream (24×36-500). The Michael addition adducts functioning as dry strength agents were added to the wet end of the papermaking machine at the level of 0.1 wt % vs. dry paper pulp. The paper was cured at 80° C. for 0.5 hr. Dry tensile strength, dry stretch, dry tear, ring crush, and Mullen burst were used to measure the dry strength effects.
The dry strength test results are shown below in Table II. The performance of the resin compositions was expressed as a percentage increase over the dry strength of paper made without additives.
TABLE II
Dry strength Results of the Examples
Dry
Dry
Dry
Mullen
Ring
Tensile
Stretch
Tear
Burst
Crush
Example 1
108
106
120
111
111
Example 2
101
100
106
107
103
Example 3
102
103
108
109
103
Example 4
104
110
119
113
105
Hercobond ® 6363
107
100
111
110
108
Hercobond ® 6350
106
103
112
120
110
Drainage efficiency and flocculants properties of the polyvinylamine adducts are also compared with Hercobond®6363 and Hercobond® 6350 dry strength resins and the blank using the Canada Freeness Test Method. The turbidities of the filtrates were also measured to estimate flocculation property of the polymers. The evaluation results are summarized in Table III.
TABLE III
Drainage and Flocculation Results of the Examples
Turbidity
Freeness
Drainage over blank (%)
Blank
57
409
100
Example 1
42
447
109
Example 2
50
443
108
Example 3
51
429
105
Example 4
48
454
110
Hercobond ® 6363
45
476
117
Hercobond ® 6350
46
450
110 | Several Michael addition adducts of vinylamines with α,β. -unsaturated alkyl carbonyl compounds including amides, esters and acids, particularly acrylamide are presented. Additionally, a process for producing these Michael addition adducts is described. These adducts are generally useful in the manufacture of paper and are particularly useful as dry strength additives to make paperboard products using a papermaking machine. | 3 |
This is invention relates to CNC machine tools and more particularly to a machine tool having improved versatility and productivity. The invention further contemplates an improved toolhead assembly for such a machine.
BACKGROUND OF THE INVENTION
In CNC machine tools used in performing various machining operations on workpieces formed of wood, plastic or nonferrous metals, there basically is provided a base member, a table mounted on the base member which may be either stationary or displaceable along a longitudinal or y-axis, a gantry mounted on the base member which may be stationary or displaceable along such y-axis, a toolhead support assembly mounted on the gantry, displaceable transversely or along an x-axis and a toolhead assembly mounted on the toolhead support assembly and displaceable along a vertical or z-axis. The various components of such a machine are displaced along several lines of travel or axes by servomotors operated by a programmable controller.
Over the years, in an effort to increase versatility and productivity, such machines have been modified to provide various forms of improved tooling features such as automatic tool changers, "piggyback" type toolhead assemblies utilizing an additional tool spindle operated by the main tool spindle drive and multiple toolhead assemblies. While such forms of toolhead assemblies have provided for improved versatility and productivity, they also have had certain attendant disadvantages. While an automatic tool changer provides greater versatility, it still requires a number of motions of the toolhead assembly in maneuvering which has the effect of reducing cycle time. While a "piggyback" type of assembly is quicker to operate and less costly than automatic tool changers, it is limited with respect to the number of tools available for performing different work functions. With regard to multiple toolhead assemblies, while such arrangements provide greater versatility and productivity, they have the disadvantage of being comparatively costly and incapable of being positioned at all points of the machine table due to the presence of multiple assemblies which restrict their degree of movement.
It thus has been found to be desirable to provide a type of machine as described which not only improves upon the versatility and production of similar prior art machines but which overcomes the several disadvantages attendant to prior art toolhead assemblies.
SUMMARY OF THE INVENTION
The present invention overcomes the various disadvantages of prior art toolhead assemblies by providing a machine of the type described having a tool assembly generally consisting of a support means mountable on the machine tool, a housing mounted on the support means rotatable about a given axis relative to the support means, a plurality of tools mounted on the housing, having axes radially disposed and circumferentially spaced relative to the given axis, means connectable to power sources of the machine for selectively operating each of the tools when each selected tool is disposed in a predetermined position relative to the support means, means operatively interconnecting the support means and housing for selectively, rotatably indexing the housing about the given axis to position a selected one of the tools in the predetermined position, and means for locking the housing relative to the support means when a selected one of the tools is disposed in the predetermined position.
The tools mounted on the housing may be either pneumatically or electrically operated or a combination thereof. The means for selectively operating such tools includes means for communicating a source of air under pressure with each pneumatically actuated tool when such tool is disposed in the predetermined position, and electrical contact means which engage when each of the electrically operated tools is disposed in the predetermined position. Means further are provided for identifying the type of tool disposed in the predetermined position so that the appropriate mode of motive force corresponding to the particular tool disposed in the predetermined position may be supplied.
The locking means for such assembly includes an extendable pin disposed in one of the support means and the housing, and a pin receiving opening in the other of the support means and the housing, registrable with the extendable pin when a selected tool is disposed in the predetermined position. Preferably, the extendable pin includes a tapered end portion engageable with a side wall portion of an opening in which it is received for camming the tool into the predetermined position under conditions where the selected tool may not be precisely positioned in the predetermined position.
The indexing means for the housing of the assembly preferably includes a roller bearing having an inner race rigidly secured to the support means and an outer race rigidly secured to the housing supporting the various tools. The housing is rotatably indexed relative to the support means by means of a motor having a pinion disposed in frictional drive relationship with the outer race of such bearing. The frictional drive not only prevents the transmission of loads back through the gear reduction train of the indexing motor but further permits the camming action of the locking pin as it is extended into a registrable opening in the outer race of the bearing under such conditions when the selected tool is not precisely positioned in the predetermined position for performing a work function.
Other objects and advantages of the present invention will become more apparent to those persons having ordinary skill in the art to which the present invention pertains from the following description taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a CNC machine tool embodying the present invention;
FIG. 2 is an enlarged, side elevational view of the machine shown in FIG. 1, illustrating the toolhead assembly thereof and having portions thereof broken away;
FIG. 3 is a top plan view of the portion of the machine shown in FIG. 2;
FIG. 4 is an enlargement of the rail construction designated in FIG. 3;
FIG. 5 is an enlargement of the rail construction designated in FIG. 3;
FIG. 6 is an enlarged cross-sectional view taken along line 6--6 in FIG. 2;
FIG. 7 is an enlarged cross-sectional view taken along line 7--7 in FIG. 2;
FIG. 8 is a perspective view of the inner side of the toolhead assembly shown in FIG. 2, having portions thereof broken away;
FIG. 9 is an enlarged, vertical cross-sectional view of the locking pin assembly shown in FIGS. 2 and 3;
FIG. 10 is a perspective view of the locking pin shown in FIGS. 8 and 9;
FIG. 11 is an enlarged, side elevational view of a power supply rod used in the toolhead assembly shown in FIGS. 2, 3, 6 and 7;
FIG. 12 is an enlarged, vertical cross-sectional view of the rotary union mounted on the free end of the power supply rod shown in FIG. 11;
FIG. 13 is an enlarged, cross-sectional view taken along line 13--13 in FIG. 11;
FIG. 14 is an enlarged, cross-sectional view taken along line 14-14 in FIG. 11;
FIG. 15 is an enlarged view of the trip switch designated in FIG. 11;
FIGS. 15a through 15e are enlarged, trip elements cooperable with the trip switch shown in FIG. 15;
FIG. 16 is a view similar to the view shown in FIG. 11, illustrating a pneumatically powered tool supported on the housing of the toolhead assembly, in an operative position;
FIG. 17 is a cross-sectional view taken along line 17--17 in FIG. 16;
FIG. 18 is a view similar to the view shown in FIG. 16, illustrating an electrically powered tool in an operative position;
FIG. 19 is a cross-sectional view taken along line 19--19 in FIG. 18;
FIG. 20 is a view similar to the view shown in FIG. 18, illustrating another electrically powered tool in the operating position; and
FIG. 21 is a cross-sectional view taken along line 21--21 in FIG. 20.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings, there is illustrated an embodiment of the invention which generally includes a base member 30, a worktable 31, a gantry 32, a toolhead support assembly 33 and a toolhead assembly 34. The base member is formed of steel sections welded together to provide a rigid end stable foundation. Worktable 31 is mounted horizontally on the base member and is adapted to be displaced longitudinally relative to the base member or along a y-axis. Gantry 32 includes a pair of leg members 35 and 36 rigidly secured at their lower ends to the base member, and a transversely disposed section 37 supported on the leg sections and spanning above the worktable. The front face of transverse section 37 is provided with a pair of vertically spaced, transversely disposed rails 38 and 39 on which toolhead support assembly 33 is mounted and displaceable transversely or along an x-axis. Toolhead assembly 34 is mounted on the toolhead support assembly is adapted to be displaced vertically or along a z-axis. Each of worktable 31, toolhead support assembly 33 and toolhead assembly 34 is displaceable along its respective axis by a feedscrew arrangement driven by an AC servomotor. The operation of such servomotors is controlled by a programmable controller to provide for the movement of a tool mounted on the toolhead assembly along a motion path to perform a work function such as routing, shaping, drilling, sanding and the like on a workpiece mounted on the worktable. Instead of the worktable being displaceable and the gantry being stationary as described, the worktable can be stationary and the gantry may be displaceable along the y-axis to provide the displacement between the gantry and the worktable.
Toolhead Support Assembly
As best shown in FIGS. 2 and 3, the toolhead support assembly is provided with a rearwardly disposed support plate 40 which is provided with a set of upper, rearwardly projecting brackets 41, 41 slidably mounted on upper rail 38, and a set of lower, rearwardly projecting brackets 42, 42 slidably mounted on lower rail 39 for guiding the toolhead support assembly on rails 38 and 39 along the transverse or x-axis. Such displacement is provided by a feedscrew 43 journaled in bearings provided on transverse gantry section 37, driven by a servomotor and cooperating with a follower 44 secured to the rear side of support plate 40. Secured to and projecting forwardly from support plate 40 is a pair of transversely spaced brackets 45 and 46, provided at their forward ends with a pair of transversely spaced, vertically disposed rails 47 and 48. Mounted on rails 47 and 48 is a mounting plate 49 on which the toolhead assembly is mounted and which is displaceable vertically or along an x-axis relative to the toolhead support assembly.
Displacement of the toolhead assembly relative to the toolhead support assembly vertically or along the z-axis is provided by a vertically disposed feedscrew 50 journaled in a bracket 51 mounted on support plate 40, and cooperating with a follower member 52 rigidly secured to mounting plate 49 by means of a bracket 53. Feedscrew 50 is driven by a motor 54 mounted on a bracket 55 secured to support panel 40, through a pulley assembly 56. It will be appreciated that as the drive motor 54 is operated, the feed screw will cooperate with follower member 52 to cause the toolhead assembly to displace relative to the toolhead support assembly, guided along rails 47 and 48.
Toolhead Assembly
Referring to FIGS. 6 through 12 of the drawings, toolhead assembly 34 generally includes a power supply rod 60 secured at one end to support plate 49, a housing or turret 61 supported on support plate 49 for rotational movement about the axis of power supply rod 60, a first set of electrically powered tools 62 through 65 and a set of pneumatically powered tools 66 through 69 mounted on housing 61 with the spindle axes thereof disposed radially and circumferentially spaced relative to the axis of the power supply rod, a rotary indexing assembly 70 (FIGS. 2 and 3), a pin locking assembly 71 and a tool identification assembly 72. Housing 61 consists of a pair of octagonally configured front and rear walls 73 and 74, and a plurality of side wall sections 75 through 82. The housing is mounted concentrically relative to the axis of the power supply rod and is rotatably supported on mounting plate 49 by means of a roller bearing 83, as best shown in FIGS. 7 and 8. The inner race 84 of the roller bearing is rigidly connected to support plate 49 and the outer bearing 85 thereof is rigidly secured to rear wall 74 of the housing. It will be appreciated that upon rotation of outer race 85 of roller bearing 83, housing 61 will be caused to rotate relative to mounting plate 49 about the axis of the power supply rod.
Power Supply Rod
The function of power supply rod 60 is to provide an electrical power connection to each of the electrically powered tools 62 through 65 as each of such tools is indexed to a lower operative position as shown by electrically powered tool 64 in FIG. 6, provide a connection of each pneumatically powered tool 66 through 69 to a source of air under pressure as each such tool is indexed to the lower operative position, and further identify by means of assembly 72 the particular tool disposed in the operative position to allow the controller to supply the appropriate type of power for operating the tool disposed in the operative position. The rod is formed of a sturdy metal, having the inner end thereof rigidly secured to mounting plate 49. Electrical power for the 3-phase, AC motor of each of the electrically powered tools is provided through knife-type electrical contacts. Such contacts include three sets of stationary clip contacts 86, 87 and 88 supported on and depending from an intermediate portion of the power supply rod, and a cooperating set of blade contacts mounted on each electrically powered tool which are adapted to engage the clip contacts when the tool is positioned below the power supply rod in the operative position. The stationary clip contacts are provided with electrical lead lines which extend through a passageway in the power supply rod and are operatively connected to the power supply of the machine, and each set of movable blade contacts is connected to the windings of the respective tool motor, in the conventional manner.
Air under pressure for operating each of the pneumatically powered tools 66 through 69 disposed in the operative position is supplied from a source on the machine, through a passageway 89 in the power supply rod, as best shown in FIGS. 13 and 14, and a rotary union assembly 90 mounted on the outer end of the power supply rod. As best seen in FIGS. 11 and 12, rotary union assembly 90 includes a support pin 91, a cylindrical block member 92, an annular end cap 93 and an annular valve plate 94. Support pin 91 is disposed coaxially with the power supply rod and includes a head portion 95 engaging an outer side of a diametrically disposed member 96 connected at its ends to opposed side wall sections of the housing, and a shank portion 97 extending through an axially disposed opening 98 in the block member and having the end thereof threaded into an end wall 99 provided with an outlet port of air passageway 89. Block member 92 includes an outer circular wall 100, an inner circular wall 101 and a cylindrical outer wall 102. Outer wall 100 is secured to diametrically disposed member 96 by means of a set of screws 103 and 104 thus causing block member 92 to rotate with the housing relative to power supply rod 60 and support pin 91 about the common axis of the power supply rod and support pin 91. Inner end wall 101 is provided with a recess 105 having a cylindrical bottom wall 106 and a cylindrical side wall 107. Annular end cap member 93 is secured to end surface 101 of the block member by means of a set of screws 108 to engage an annular wall of the power supply rod and thus close recess 105 to form an annular chamber 109 in which annular valve plate 94 is disposed.
Cylindrical block member 92 further is provided with a plurality of threaded ports 110 in cylindrical wall 102 which are circumferentially spaced 90° apart relative to the center line of support pin 91. Each of such ports communicates with chamber 109 by means of a passageway 111 having a radially disposed segment 111a and a segment 111b disposed equidistantly from and parallel to the axis of support pin 91. Each of ports 110 is connected to a motor of one of pneumatically powered tools 66 through 69 by means of a flexible air hose.
Annular valve plate 94 is urged into engagement with end wall 99 of the power supply rod to block the outlet port of air supply passageway 89, by means of a helical retaining spring 112 interposed between a shoulder provided on the shank portion of support pin 91 and an outer end wall of the annular valve plate. As best shown in FIG. 12, a lower portion of annular valve plate 94 is provided with a passageway 113 which is radially displaced and parallel relative to the axis of support pin 91, and which further is adapted to be aligned with a segment 111b of a passageway 111 communicating with a lowermost, vertically disposed outlet port 110.
During the rotational indexing of the turret to reposition the tools thereon, annular valve plate 94 will remain stationary with power supply rod 60 and support pin 91, urged against end wall 99 of the power supply rod under the biasing action of spring 112 to block the outlet port of air supply passageway 89, and cylindrical block member 92 secured to member 96 and annular end cap member 93 secured to the cylindrical block member will rotationally index with the housing about the common axis of the power supply rod and support pin 91. Under such conditions, there would be no air under pressure supplied to any of passageways 111, and annular valve plate 94 will be out of engagement with cylindrical block member 92 thus preventing any interference with the freely rotational indexing movement of the housing or any wear between any engaging surfaces of the annular valve plate and the cylindrical block member.
When an air powered tool is indexed to the lower, operational position and such condition is signalled to the controller by the tool identification assembly, air under pressure is supplied to passageway 89 which causes it to bear against annular valve plate 94 and displace it axially against the biasing action of retaining spring 112. Under such conditions, air under pressure will flow through the space formed between end surface 99 of the power supply rod and the displaced annular valve plate, passageway 113 and registered passageway 111 communicating with the lowermost outlet 110 to operate the pneumatically powered tool disposed in the operative position. When the operation of the tool has been completed and the supply of pressurized air to passageway 89 has been discontinued, retaining spring 112 will then extend to axially displace the annular valve plate in the position as shown in FIG. 12, blocking the outlet of air passageway 89 and permitting the cylindrical block member and the housing to freely rotate to position the next tool.
Rotary Indexing Assembly
Rotary indexing assembly 70 is best illustrated in FIGS. 2 and 3. It consists of a drive motor 120 mounted on a bracket 121 secured to the inner side of support plate 49, having a downwardly projecting shaft operatively connected to a gear reduction unit 122 also mounted on the inner side of support plate 49. Operatively connected to an output shaft of the gear reduction unit is a pinion 123 extending through an opening in the support plate, and engageable with an outer cylindrical surface 124 of outer race 85 of roller bearing 83, in frictional drive relationship. The end portion of pinion 123 is provided with a layer of a compressible, friction material such as polyurethane which causes the pinion to sufficiently engage cylindrical surface 124 of the outer race of bearing 83 to transmit rotary motion through frictional contact.
In the operation of assembly 70 for indexing the toolhead assembly and positioning a selected tool in the operative position, the controller of the machine functions to operate drive motor 120 and provide an output drive in a selected direction which is transmitted through the gear reduction unit and pinion 123 to outer race 124 and thus correspondingly rotationally index the selected tool on the toolhead assembly to or closely to the operative position. In the event the selected tool intended to be indexed to the operative position is not precisely located in such position, locking pin assembly 71 as shown in FIG. 9 functions to cam the outer race portion of roller bearing 83 so that the selected tool is nudged into the precise operating position. Any reactive or other force transmitted back through the outer race of the bearing will be prevented from being transmitted to pinion 123 and the gear reduction unit by the ability of the bearing outer race to slip relative to the pinion, thus preventing any possible damage to any gear reduction unit components.
Pin Locking Assembly
The precise positioning of a selected tool of the turret assembly in the operative position and a locking of the toolhead assembly relative to support plate 49 is provided by pin locking assembly 71. Such assembly is best shown in FIGS. 7 through 10 and consists of a bracket 130 mounted on an inner side of support plate 49 and having a hub portion thereof extending through an opening in the support plate, a pneumatically actuated cylinder assembly 131 mounted on bracket 130 and having an output shaft extendable through an opening in the hub portion of bracket 130, and a locking pin 132 mounted on the end of the extendable rod of assembly 131 which is adapted to be disposed within the hub portion of bracket 130 when the extendable rod of assembly 131 is in a retracted position, as shown in FIG. 9, and be disposed within an opening 133 disposed in an outer face 134 of bearing outer race 85 when one of such openings registers with the locking pin and the rod portion of cylinder 131 is extended, as shown in FIG. 8. Pin receiving openings 133 are circumferentially spaced on outer face 134 of the bearing outer race, and each of such openings is adapted to register with the locking pin when a tool is positioned in the operative position.
Referring to FIG. 7, it will be noted that when tool 64 is located at or near the operative position as shown, the opening displaced 90°, in a clockwise direction, will be positioned at or near registry with the locking pin. If such opening is precisely registered with the locking pin, the rod portion of cylinder 131 will merely extend will merely extend to freely insert the locking pin into the registered opening to lock the toolhead assembly relative to support plate 49. If such opening is slightly displaced from precise registry with the locking pin, the extension of the rod portion of the cylinder will cause the locking pin to cam the outer race causing it to rotationally index slightly and thus cause the pin receiving opening to register precisely with the locking pin and correspondingly to cause the selected tool to be positioned in the precise operating position.
As best shown in FIG. 10, locking pin 132 includes a cylindrical main body portion 133 which rides in a bushing 134 disposed in the opening of the hub portion of bracket 130, and a tapered end portion 135. Preferably, each of pin receiving openings 133 is provided with an outer, tapered wall portion engageable by tapered portion 135 of the locking pin to facilitate the camming action of the pin upon the pin being inserted into a partially registered opening.
To provide an effective and smooth functioning of the locking assembly, a greater force is applied in retracting the locking pin than the force applied in extending the pin. As an example, air pressure of about 40 psi is provided to the base end of cylinder assembly 131 for extending the locking pin and air pressure of about 90 psi is provided to the rod end of cylinder assembly 131 for retracting the locking pin. The greater retracting force assures that the locking pin will not become wedged or jammed in a registered pin receiving opening thus interfering with the indexing operation of the toolhead assembly.
In the operation of the locking pin assembly, whenever the rotary indexing assembly is operated to position a tool at or near the precise operative position of the tool, the controller will function to actuate cylinder assembly 131 causing the rod portion thereof to extend and thus insert the locking pin into a pin receiving opening 133 disposed at or near precise registry with the locking pin. If the pin receiving opening is precisely registered, the locking pin will easily be inserted into the registered opening to lock the toolhead assembly relative to support plate 49. If such pin receiving opening is not precisely registered with the locking pin, resulting in the selected tool not being properly located in the precise operative position, the insertion of the locking pin into the nearly registrable pin receiving opening will cause the pin to cam the outer bearing race and thus nudge the toolhead assembly and correspondingly rotate the selected tool in the precise operative position. When the work function of the tool disposed in the operative position has been completed and another tool is to be indexed into the operative position, the controller of the machine will function to cause cylinder assembly 131 to retract the rod portion thereof and thus withdraw the locking pin from the pin receiving opening in the bearing outer race to free the toolhead assembly.
Tool Assemblies
FIGS. 16 and 17 illustrate pneumatically operated tool 68 disposed in the operative position. The tool includes an air motor 140 mounted on an inner side of side wall section 80 of housing 61, having a portion thereof including an output shaft extending through an opening in side wall section 80 and having a tool bit removably attached on an end portion thereof, an air supply hose 141 connected to a lowermost disposed outlet opening 110 in rotary union assembly 90 and an arm member 142 disposed radially relative to the axis of the power supply rod and having a trip element 143 disposed on the free end thereof which is adapted to trip a depressible switch element of assembly 72 and thus identify for the controller that tool 68 is disposed in the operative position as will later be more fully explained.
When tool 68 is in the operative position as shown in FIGS. 16 and 17, the computer will operate to cause air under pressure to be supplied to fluid passageway 89 thus causing annular valve plate 94 of assembly 90 to displace against the biasing action of retaining spring 112, and flow through the space between end face 99 of rod 60 and annular valve plate 94, passageway 113 registered with segment 111b of passageway 111, passageway 111 and air hose 141 to operate air motor 140. When the work function of tool 68 has been completed, the controller will operate to discontinue the supply of air under pressure to passageway 89 thus causing annular valve member 94 to displace and close the outlet port of passageway 89, under the biasing action of retainer spring 112.
FIGS. 18 and 19 illustrate electrically powered tool 64 disposed in the operative position. The tool includes a 3-phase, 9 H.P., AC motor 150 mounted on side wall section 79 of the housing having a portion thereof with an output shaft extending through an opening in side wall section 79, on which a tool bit may be removably attached, and a bracket 151 secured to the base end of motor 150 which is adapted to be disposed substantially radially relative to the axis of the power supply rod and adjacent the sets of electrical contact clips 86, 87 and 88. Provided on bracket 151 and electrically connected to the windings of motor 150 are sets 152, 153 and 154 of electrical contact blades which engage sets of electrical contact clips 86, 87 and 88, respectively, in electrical contact to provide electrical power to motor 150. When blade sets 152, 153 and 154 engage electrical clips sets 86, 87 and 88, a trip element 155 mounted on bracket 151 will be disposed in relationship to assembly 72 for identifying tool 64 as the tool located in the operative position.
With tool 64 positioned in the operative position as shown in FIGS. 18 and 19, the tool identification assembly will signal the controller of the type of tool to be powered. Accordingly, the controller will operate to supply the appropriate voltage through the knife-type contacts to energize and thus operate tool 64.
FIGS. 20 and 21 illustrate electrically powered tool 65 disposed in the operative position to be energized and perform a work function on a workpiece positioned on the worktable of the machine. Tool 65 is generally similar to electrically powered tool 64 and is adapted to be electrically connected to the electrical contact clips on the power supply rod in a manner similar to electrically powered tool 64. The tool includes a 3-phase, 4 H.P. AC motor 161 mounted on side wall section 81 of the housing and having an outer portion thereof extending through an opening in the side wall. The base end of the motor includes a bracket 162 disposed radially relative to the axis of the power supply rod. Mounted on an angle shaped member 163 secured to the free end of bracket 162 are sets of electrical blade contacts 164, 165 and 166 which engage electrical contact clips 86, 87 and 88, respectively, to provide an electrical connection of motor 161 with the electrical supply on the machine.
Electrically powered tool 65 is connected to the electrical power supply of the machine in the same manner as electrically powered tool 64 when tool 65 is disposed in the operative position as shown in FIGS. 20 and 21, with the electrical blade contacts thereof engaging the electrical clip contacts provided on the power supply rod. The identification of electrically powered tool 65 for the controller is provided by a trip element 167 which engages and trips certain switch elements of tool identification assembly 72 when electrically powered tool 65 is positioned in the operative position. Upon identification of tool 65 being positioned in the operative position, the controller will function to apply electrical current of an appropriate voltage to electrical motor 161 through the electrical knife connections. Once electrically powered tool 63 is rotatably indexed out of the operative position as shown in FIGS. 20 and 21, the controller further will function to discontinue the supply of electrical current for motor 161.
Electrically powered tools 62 and 63 are configured and are electrically energized similar to electrically powered tools 64 and 65, as described. Similarly, air powered tools 66, 67 and 69 are constructed and are connected with a source of air under pressure similar to air powered tool 68, as described. In this latter regard, it will be appreciated that each of air powered tools 66, 67 and 69 will be connected by means of a flexible air hose to an outlet port 110 of rotary union assembly 90 and will be caused to be powered when such tool is disposed in the operative position and the controller operates to supply air under pressure to passageway 89 in the power supply rod.
Various types of tool bits may be mounted on the various electrical and air powered tools as described such as routers, drills, shapers, sanders and the like, as desired.
Tool Identification Assembly
Tool identification assembly 72 shown in FIG. 15 essentially consists of an electrical switch having a set of downwardly biased elements 171, 172 and 173. Such elements may be depressed in different configurations to generate different identification signals to the controller. The switch elements are adapted to be engaged and depressed in various combinations by the trip elements of different configurations shown in FIGS. 15a through 15e, mounted on the electrical and air powered tools, to identify the particular tool disposed in the operative position to be supplied with a motive force. As an example, trip element 167 of electrically powered tool 65, having a raised portion 167a in a first sector thereof, a void portion in a second sector thereof and a raised portion 167c in a third sector thereof will be adapted to engage and depress switch elements 171 and 173 to close two sets of contacts and energize two circuits noting the presence of electrically powered tool 65 in the operative position. Trip element 155, mounted on electrically powered tool 64 and having no voids in any of the three sectors thereof, will engage all three switch elements 171, 172 and 173 to depress the same, causing three sets of contacts to close and energizing three separate circuits noting the presence of electrically power tool 64 in the operative position. Trip element 143 provided on air powered tool 68 and having voids in the first and third sectors and a raised portion 143b in the second sector is adapted to engage and depress only switch element 172 to close a single pair of contacts and energize a single circuit denoting the presence of air powered tool 68 in the operative position. Other tools mounted on the housing are provided with similar trip elements, each having a different configuration engageable with switch elements 171, 172 and 173 in different combinations to similarly close different sets of contacts and energize different combinations of circuits to denote the particular electrical or air powered tool disposed in the operative position.
Operation
In the operation of the machine as described, one or more workpieces to be machined are properly positioned on workpiece support table 31 and a program providing for a sequence of tool selection and the path and feed rate of each tool is inputted into the controller of the machine. When the controller then begins to execute the program, it functions to operate servomotor 70 to rotationally index the housing or turret 61 and thus position a selected tool such as electrically powered tool 64 in the operative position as shown in FIGS. 2, 6, 7, 18 and 19 to begin a first machining operation. When the housing or turret is thus oriented, an opening 133 in the bearing outer race 85 will either fully or partly register with locking pin 123. The controller then functions to apply air under pressure to the base end of cylinder assembly 131 to extend locking pin 123 into the fully or partially registered opening 133. In the event the opening is only partially registered with the locking pin, denoting a slight displacement of electrically powered tool 64 from the operative position, the engagement of tapered portion 135 of the locking pin with a side wall portion of the opening will cam the housing and thus displace the electrically powered tool 64 precisely to the operative position.
As tool 64 indexes to the operative position, sets of blade contacts 152, 153 and 154 will engage electrical contact clips 86, 87 and 88, respectively, and trip element 155 will depress all three switch elements of assembly 72 to identify the presence of tool 64 in the operative position. Upon notification of the presence of such tool, the controller will function to provide the appropriate power supply for operating the motor of tool 64. Then, in continuing to execute the program, the controller will function to operate the various servomotors of the machine to cause the tool bit of the tool disposed in the operative position to displace relative to the workpiece and thus perform a work function prescribed for such tool in accordance with the program.
When the program may call for the use of an air powered tool such as tool 68, the controller will function to cause air under pressure to be supplied to the rod end of cylinder assembly 131 to retract locking pin 132 and permit housing 61 to freely rotate, and cause drive motor 70 to be energized and thus cause housing 61 to index to position air powered tool 68 in the operative position. Cylinder assembly 131 is then again operated to insert the locking pin in a fully or partially registered opening 133 to accurately position the tool and lock toolhead assembly to support plate 49. As tool 68 is indexed into the operative position, trip element 143 will cause switch element 172 to depress and close a set of contacts, energizing a circuit and identifying for the controller the tool disposed in the operative position. Under such circumstances, the controller will function to provide a supply of air under pressure through passageway 89 in the power supply rod to displace annular valve plate 94 in the rotary union assembly and flow through communicating passageways 113 and 111 to operate air motor 140. The controller will then continue to function to operate the various servomotors for each of the axes of the machine to continue to execute the program.
In continuing to execute the program, the operation as described is repeated to position other electrical and air powered tools mounted on the housing in the operative position to perform subsequent machining functions. Each time the housing is to be indexed, the locking pin is retracted and extended in the manner described to not only precisely position the selected tool in the operative position but also to lock the toolhead assembly relative to the support plate thereof. In circumstances where reactive and other loads are applied to the housing which normally would be transmitted through the pinion to the gear reduction unit, such load transmission is prevented as a result of the capability of the bearing outer race to slip relative to drive pinion 123.
The machine as described not only provides a greater versatility of operation by reason of the number of different tools available but also an improved productivity in providing fast cycle times in changing tools. Furthermore, the machine as described is advantageous in that it requires a minimal operator involvement other than loading and unloading workpieces.
From the foregoing detailed description, it will be evident that there are a number of changes, adaptations and modifications of the present invention which come within the province of those having ordinary skill in the art to which the aforementioned invention pertains. However, it is intended that all such variations not departing from the spirit of the invention be considered as within the scope thereof as limited solely by the appended claims. | The invention provides a machine tool comprising a base member, a workpiece support means mounted on the base member, a toolhead support means mounted on the base member, a toolhead assembly mounted on the toolhead support means, rotatable about a given axis relative to the toolhead support means, at least two tools mounted on the toolhead assembly, having axes radially disposed and circumferentially spaced relative to the given axis, a means for operating a selected one of the tools when the selected tool is disposed in a predetermined position relative to the workpiece support means operatively interconnecting the toolhead support means and the toolhead assembly for selectively, rotatably indexing the toolhead assembly about the given axis to position a selected one of the tools in the predetermined position; and means for locking the toolhead assembly relative to the toolhead support means when a selected one of the tools is disposed in the predetermined position. | 8 |
[0001] The present invention relates to a yarn-feeding/recovering method for textile machines and to an apparatus for carrying out such method.
BACKGROUND OF THE INVENTION
[0002] In the textile field, well feeders are known which are provided with a stationary drum on which a motorized swivel arm winds a plurality of yarn loops forming a stock. The yarn, which is unwound from the drum upon request of a textile machine arranged downstream, is subject to a stabilizing brake that maintains the unwinding yarn under a slight tension. The stabilizing brake typically comprises a frustoconical hollow member which is biased with its inner surface against the delivery edge of the drum by manually adjustable elastic means.
[0003] As described in EP 2031106, in order to maintain the feeding tension substantially constant, a controlled brake may be arranged downstream of the feeder, e.g., a foil-based brake of the type described in EP 0622485. This brake is controlled by a feedback loop which receives a measured tension signal from a sensor, then compares it with a reference tension which is indicative of a desired tension, and finally modulates the braking action in such a way as to minimize the difference between the reference tension and the measured tension.
[0004] Feeders are also known in which the yarn is wound on a rotary drum, which draws the yarn from a reel and feeds it to the downstream textile machine In this case, the tension of the yarn unwinding from the feeder is controlled by modulating the speed of rotation of the drum, always on the basis of a signal received from a tension sensor as in the previous case. Accordingly, in other words, the change of tension to be applied is determined by the difference between the yarn-feeding speed and the yarn-drawing speed set in the downstream machine
[0005] As known, certain particular processes, e.g., weaving the heel of socks, require that the yarn fed to the machine is periodically recovered and then returned. This operation is usually carried out by a dedicated recovering device arranged upstream of the machine
[0006] A recovering device of this type is described in EP 1741817 and essentially comprises a motorized reel having an oblique passage defined therein, through which the yarn runs. The passage extends between an inlet port which is axially formed on an end surface of the reel, and an outlet port which is formed on the cylindrical, lateral surface of the reel. When an amount of yarn must be recovered, the downstream machine sends a signal to the recovering device which enables the rotation of the reel, so that the yarn is wound upon the reel.
[0007] As well known to the person skilled in the art, a critical issue of the above systems consists in coordinating the operation of the braking system, which operates on the basis of the measured tension of the yarn, with the operation of the recovering system, which is enabled in response to commands sent from the downstream machine on the basis on a predetermined pattern, with consequent difficulties in accurately controlling the feeding parameters and the state of the yarn during the recovering steps, e.g., in relation to possible, accidental events which may occur, such as a yarn breakage.
SUMMARY OF THE INVENTION
[0008] It is a main object of the present invention to provide a method in which the yarn-feeding function and the yarn-recovering function are coordinated with each other in a more reliable and more accured manner with respect to the prior art, particularly in relation to the control of the yarn tension during the recovering step and to the reaction in case of accidental events, such as a yarn breakage; it is also an object to provide an apparatus for carrying out such method.
[0009] The above objects and other advantages, which will better appear from the following description, are achieved by a method having the features recited in claim 1 , as well as by an apparatus having the features recited in claim 7 , while the dependent claims state other advantageous, though secondary features, of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The invention will be now described in more detail with reference to a few preferred, non-exclusive embodiments, shown by way of non limiting example in the attached drawings, wherein:
[0011] FIG. 1 diagrammatically shows an apparatus for carrying out the method according to the invention;
[0012] FIG. 2 is a side elevation view of a recovering device of a known type used in the apparatus of FIG. 1 ;
[0013] FIG. 3 is a view similar to FIG. 2 , which shows the recovering device in a different operative configuration;
[0014] FIG. 4 is a flowchart showing the steps of the method according to the invention;
[0015] FIG. 5 diagrammatically shows an apparatus for carrying out the method according to an alternative embodiment of the invention;
[0016] FIG. 6 is a perspective view of a yarn feeder with rotary drum, which is modified according to the invention to incorporate the apparatus of FIG. 5 ;
[0017] FIG. 7 is a front elevation view of the yarn feeder of FIG. 6 ;
[0018] FIG. 8 is a side elevation view of the yarn feeder of FIG. 6 ;
[0019] FIG. 9 is a broken away view similar to FIG. 8 , showing the yarn feeder sectioned along axis IX-IX of FIG. 7 ;
[0020] FIG. 10 is a front elevation, broken away view of the yarn feeder of FIG. 6 sectioned along axis X-X of FIG. 8 ;
[0021] FIG. 11 is a Figure similar to FIG. 7 , showing the yarn feeder to an enlarged scale and in a different operative configuration;
[0022] FIG. 12 is a flowchart showing the steps of the method according to the alternative embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0023] FIG. 1 diagrammatically shows a yarn-feeding/recovering apparatus 10 having a yarn feeder 12 provided with a stationary drum 14 and with a flywheel 16 driven to rotate by a motor 18 . The flywheel draws yarn F from a spool 20 and winds it on drum 14 in the shape of loops forming a stock.
[0024] Yarn F, which is unwound from the drum upon request of a general textile machine 22 arranged downstream, is subject to the braking action of a stabilizing brake adapted to maintain the yarn under a slight tension. The stabilizing brake conventionally comprises a frustoconical hollow member 24 which is biased with its inner surface against the delivery edge of drum 14 by elastic means 26 .
[0025] In a way known per se, yarn F coming out of stabilizing brake is further subject to the braking action of an electronic yarn-braking device (or brake) 28 which is controlled by a tension control block TC of a control unit CU (which is typically incorporated in yarn feeder 12 ). Control unit CU is programmed to modulate the braking action applied to yarn F by electronic brake 28 , on the basis of a signal received from a tension sensor 30 , in such a way as to maintain the tension of the delivered yarn substantially constant on a reference value T_ref.
[0026] The stock on drum 14 is controlled by a triad of sensors. A first sensor 51 , preferably a Hall sensor, detects the passage of magnets M integral with flywheel 16 in order to determine the amount of yarn which is wound on the drum and the winding speed. A second sensor S 2 , preferably a mechanical sensor, provides a binary information about the presence of a minimum amount of yarn at an intermediate area of drum 14 . A third sensor S 3 , preferably an optical sensor, generates one pulse UWP per each loop unwound from the drum. A speed-evaluating block SE processes signals UWP in order to calculate the yarn consumption speed on the basis of the time interval between pulses UWP, and generates an enabling signal LE which enables tension control block TC when this speed is higher than a predetermined threshold value, which is preferably equal to zero in the present embodiment. An apparatus of this type is described in EP 2031106, to which reference should be made for a more detailed description.
[0027] A yarn-recovering device 32 of the type described in EP 1741817 and shown in detail in FIGS. 2 , 3 , is arranged between electronic brake 28 and tension sensor 30 .
[0028] Yarn-recovering device 32 comprises a reel 34 keyed to a drive shaft 36 of a motor 38 , preferably a stepping motor or, alternatively, a brushless motor provided with an absolute sensor, in order to measure the real position based on techniques conventional in the field. Reel 34 is arranged with its axis A slanting at a first angle a with respect to the direction of yarn F, indicated by arrow D, so that its end surface 34 a facing away from motor 38 obliquely faces the incoming yarn. Reel 34 has an axial cylindrical seat 40 at its end surface 34 a . A passage 44 defined within reel 34 extends between an inlet port 44 a open to axial cylindrical seat 40 , and an outlet port 44 b open to the lateral, winding surface 34 b of the reel. Passage 44 is rectilinear and is slanting at a second angle b, which is substantially equal to first angle a, with respect to axis A of the reel. An internally rounded wearproof ring 46 made of ceramic is applied to the edge of cylindrical seat 40 . An inlet yarn-guide eyelet 48 and an outlet yarn-guide eyelet 50 respectively applied upstream and downstream of reel 34 are arranged at the same level of wearproof ring 46 .
[0029] Yarn F passes through upstream yarn-guide eyelet 48 , cylindrical seat 40 , passage 44 and downstream yarn-guide eyelet 50 . By operating motor 38 , as shown in FIG. 3 , the yarn downstream of the yarn-recovering device is wound on reel 34 . For a more detailed description of yarn-recovering device 32 , reference should be made to EP 1741817.
[0030] With the method according to the invention, as described in the flowchart of FIG. 4 , electronic brake 28 and yarn-recovering device 32 are alternately enabled as a function of the signals from third sensor S 3 , which are indicative of the yarn comsumption, independently from any other operative signals from downstream machine 22 .
[0031] In detail, as long as signal LE indicates that yarn is being unwound (LE=1), control unit CU continues to modulate the braking action of electronic brake 28 in such a way as to maintain the tension substantially constant at reference value T_ref, while yarn-recovering device remains at a position of minimum interference with the yarn, as shown in FIG. 2 . When signal LE indicates that yarn is no longer unwound from the drum (LE=0), which circumstance is indicative of the fact that the downstream machine has either stopped to draw yarn or started to return it, control unit CU “freezes” the braking action at the last value and, if measured tension T_meas is lower than a lower threshold tension T_lim_inf, than it enables yarn-recovering device 32 to recover yarn, while its speed V RR is continuously modulated in such a way as to maintain the tension substantially constant on reference value T_ref. At this stage, the number of revolutions and fractions of revolutions N completed by reel 34 is monitored.
[0032] It should be noted that, with the method according to the invention, reel 34 can rotate at a modulated speed in both directions. In fact, after an initial yarn-recovering step, during which the exceeding yarn is wound on reel 34 in order to maintain the tension at the desired level T_ref, the subsequent request of yarn from the downstream machine will cause reel 34 to rotate in the opposite direction always at a controlled speed, in order to return the yarn; however, before reaching the initial position (N=0) it could have to recover yarn again. When the reel reaches the initial position, control unit CU stops reel 34 , enables electronic brake 28 again, and then the cycle is repeated.
[0033] As shown in the flowchart of FIG. 4 , two emergency conditions are provided, by which the tension control is bypassed while yarn-recovering device 32 is enabled. A first condition occurs when N reaches a value N_max corresponding to the maximum amount of yarn which can be stored on the reel. In this case, the process is stopped and an alarm signal is generated. The second condition occurs when signal LE indicates that yarn is unwinding from the feeder; this means that the downstream machine is drawing yarn at a speed such that the yarn is sliding on reel 34 . In this case, the tension control is bypassed and the reel is automatically driven to rotate to its resting position N=0.
[0034] Accordingly, with this embodiment, signal LE is used as a comsumption indicator that is indicative of the delivery of yarn from the feeder and, therefore, of the withdrawal of yarn by the downstream machine; on the basis of this indicator, electronic brake 28 and yarn-recovering device 32 are alternately enabled as discussed above.
[0035] Having now reference to FIG. 5 , a weft feeder 100 is diagrammatically shown, which is provided with a motorized drum 102 on which yarn F′ is wound. Motorized drum 102 draws yarn F′ from a spool 104 and delivers it to a textile machine 106 arranged downstream. The tension of yarn F′ unwinding from the feeder is conventionally controlled in such a way as to remain substantially constant on a reference value T_ref, by a control unit CU′ (which is typically incorporated in yarn feeder 102 ) provided with a tension control block TC′ that modulates the speed of rotation V RP of drum 102 on the basis of the signals from a tension sensor 108 installed on the feeder. Accordingly, the change of tension to be applied is determined by the difference between the yarn-feeding speed and the yarn-drawing speed set in downstream machine 106 .
[0036] A yarn-recovering device 120 is arranged between motorized drum 102 and the tension sensor; in the present embodiment, it is incorporated in housing 103 of feeder 100 , as shown in more detail in FIGS. 6-11 . Yarn-recovering device 120 comprises a motorized reel 122 lying with its axis parallel to the axis of motorized drum 102 . Also in this case, the motor (not shown) of reel 122 is preferably a stepping motor or, alternatively, a brushless motor provided with an absolute sensor for measuring its real position. A passage 124 is defined within reel 122 , which extends radially between an inlet port 126 , which is formed at the middle of a free end 122 a of the reel with its axis inclined with respect to the axis of reel 122 , and an outlet port 128 formed on the lateral winding surface 122 b of the reel. Inlet port 126 and outlet port 128 are internally rounded for reducing the wear by friction.
[0037] Yarn F′ from spool 104 passes through an inlet yarn-guide eyelet 130 attached to the feeder, is wound between drum 12 and an arm 132 of a conventional tension limiter (which does not fall within the scopes of the present invention and, therefore, will not be further disclosed), runs through passage 124 which, at rest, lies at the resting position of FIG. 10 such that it substantially does not interfere with the path of the yarn, then engages a sensing element 134 of tension sensor 108 , the latter being also incorporated in housing 103 of the feeder, and finally passes through an outlet yarn-guide eyelet 136 to feed the downstream machine As shown in FIGS. 6-11 , control unit CU′ is conventially received in a seat 138 of feeder 100 , which also contains tension sensor 108 , and is provided with programming push buttons 140 and with a display 142 .
[0038] With the method according to this alternative embodiment of the invention, which is diagrammatically shown in the flowchart of FIG. 12 , drum 12 of the feeder and reel 122 of yarn-recovering device 120 are alternately enabled as a function of speed V RP of drum 102 , independently from any other operative signal from the downstream machine
[0039] In particular, as long as speed V RP of drum 102 is higher than zero, which circumstance is indicative of the fact that yarn is being delivered by the feeder and, consequently, is being drawn by the downstream machine, drum 102 continues to rotate at a modulated speed, in such a way as to maintain the tension substantially constant on reference value T_ref, while reel 122 remains at its resting position of FIG. 10 . When speed V RP of the drum becomes equal to zero, which circumstance is indicative of the fact that the feeder has stopped to feed yarn and, therefore, the downstream machine has either stopped to draw yarn or started to return it, control unit CU′ enables reel 122 to recover yarn at a speed V RR modulated in such a way as to maintain the tension substantially constant on a reference value T_ref. At this stage, the number of revolutions and fractions of revolutions N completed by reel 122 is monitored.
[0040] Similarly to the previous embodiment, reel 122 can rotate in both directions at a modulated speed. In fact, after an initial yarn-recovering step, in which the exceeding yarn is wound on reel 122 in order to maintain the tension at the desired level T_ref, the next request of yarn from the downstream machine will cause reel 122 to rotate in the opposite direction, always at a controlled speed, in order to return the yarn; however, before reaching the initial position (N=0), it could have to recover yarn again. When the reel reaches the initial position N=0, control unit CU′ stops reel 122 , enables drum 102 again, and then the cycle is repeated.
[0041] With this embodiment, there is also provided an emergency condition, by which the tension control can be bypassed. In particular, when N reaches a value N_max corresponding to the maximum amount of yarn which can be stored on the reel, the process is stopped and an alarm signal is generated. Accordingly, with this embodiment the speed V RP of the drum is used as a comsumption indicator, which is indicative of the delivery of yarn by the feeder and, consequently, of the withdrawal of yarn by the downstream machine; on the basis of this indicator, drum 102 and reel 122 are alternately enabled according to the above method.
[0042] A few preferred embodiments of the invention have been described herein, but of course many changes may be made by a person skilled in the art within the scope of the claims. In particular, in the first described embodiment a stabilizing brake as described in EP 1059375, which applies a controlled braking action to the unwinding yarn, could be used in lieu of electronic brake 28 . Moreover, in the described embodiments, the yarn-recovering device is always positioned in such a way that, at rest, it can assume positions not interfering with the yarn, as shown in FIG. 2 for the first embodiment and in FIG. 10 for the second embodiment. However, depending on the layout of the textile line, the reel could be arranged in such a way as to deviate the yarn even at its resting position in which it applies the minimum braking action upon the yarn.
[0043] The disclosures in Italian Patent Application No. TO2012A000261 from which this application claims priority are incorporated herein by reference. | A textile machine receives yarn from a yarn-feeding device via a yarn-recovering device provided with a motorized reel having a passage for the yarn, which extends between an inlet port open to the middle of the free end of the reel and an outlet port formed on the lateral surface of the reel; the tension of the yarn being maintained constant on a reference value by adjusting elements, on the basis of a measured tension signal generated by a sensor; a consumption indicator being obtained to detect an interruption in the delivery of yarn, the adjusting elements being temporarily disabled and the yarn-recovering device being temporarily enabled to rotate at a speed modulated on the basis of the measured tension signal for maintaining the tension of the yarn constant on the reference value, if an interruption in the delivery of yarn is detected. | 3 |
BACKGROUND OF THE INVENTION AND RELATED ART STATEMENT
[0001] The present invention relates to a metal gasket such as a gasket for an exhaust manifold for an engine, or a cylinder head gasket.
[0002] When a joint surface between an exhaust manifold and an exhaust pipe for an automobile engine, or a joint surface between a cylinder head and a cylinder block (cylinder body) is sealed, a metal gasket is clamped between these members to seal combustion gas, coolant water, and lubrication oil.
[0003] Such a metal gasket is made by a design method, in which, mainly as sealing means, a full bead with a projected cross-section and a half bead with a step-like (crank-like) cross-section are arranged near the perimeter of a seal target hole. Among them, the half bead can be produced at a low cost, and easily sealed by a small fastening force, so that it is widely used for gasoline engines with a small fastening force compared to diesel engines.
[0004] With respect to the metal gasket with this half bead, there is a case in which a straight line portion is created in the gasket for the exhaust manifold when the gasket is seen in plan depending on the shape of an attached member. This straight line portion has proven to cause a problem such as water leakage or oil leakage during engine operation as compared to a curved line portion. It is commonly believed that the reason the straight line portion easily creates the above-mentioned problem is that a creep relaxation in the straight line portion of the half bead increases during the operation of an engine wherein the gasket is equipped, so that the seal surface pressure partially decreases.
[0005] Therefore, when the half bead forms a straight line in a plan view, if the straight line part extends, the half bead has less resistance to a compressive force compared to the full bead. Accordingly, the creep relaxation is generated in this half bead, so that the seal quality cannot be fully exerted.
[0006] For one solution for the above-mentioned problem, metal gaskets, such as those shown in Japanese Patent Publication No. 2004-92475, are formed by arranging a pair of half beads symmetrically in a thickness direction around a liquid hole which is formed substantially in a square or a rectangular shape. Also, outlines of corner parts of the half beads are formed in a shape with a radius which is larger than that of a corner part of the liquid hole. As a whole, the metal gaskets have a shape extending in a smooth circular shape. However, in order to form this kind of half beads, a space is required around the liquid hole (seal target hole), so that they are not practical.
[0007] On the other hand, even in the cylinder head gasket, as the weight and size of an engine have been reduced, an engine member tends to have a lower rigidity, and the deformation volume of the cylinder head which repeatedly occurs by engine operation has increased. Accordingly, a force compressing the half bead also increases, so that the serious problem is a creep relaxation of the half bead.
[0008] In addition, in the metal gaskets, the tightening pressure differs depending on the distance from the tightening bolt bore, so that the seal surface pressure generated in the half beads is also uneven. As a result, the creep relaxation occurs sporadically.
[0009] In view of the problems described above, the present invention has been made such that the metal gasket prevents the creep relaxation in the half bead formed around the seal target bore of the metal gasket. Also, the metal gasket widens the distribution of the surface pressure generated in the half bead and prevents a scratch in the member clamping the metal gasket, hereby securing an excellent seal quality.
[0010] Further objects and advantages of the invention will be apparent from the following description of the invention.
SUMMARY OF THE INVENTION
[0011] In order to achieve the objects described above, according to the present invention, a metal gasket includes a seal target bore and a half bead surrounding the seal target bore. The metal gasket is provided with a surface pressure assistance plate forming depressions and projections with respect to a thickness direction inside the half bead, all around the half bead or in a part of the perimeter of the half bead. The depressions and the projections are only required relative to at least one side of the standard line of a plate of the surface pressure assistance plate, and are not necessarily required relative to both sides.
[0012] According to the structure, the surface pressure assistance plate forming the depressions and the projections is arranged with respect to the thickness direction, so that compressibility of the half bead can be enhanced due to an elastic effect by the depressions and the projections of the surface pressure assistance plate, and creep relaxation of the half bead can be prevented.
[0013] Also, members disposed on both sides of the metal gasket and abutting against the half bead hit a corner part of the half bead from an area close to a narrow line to an area of a wide surface. In addition, the maximum value of the surface pressure can be decreased and the surface pressure can be reduced, and the surface pressure generated on the half bead, especially, the surface pressure generated at the corner part of the half bead can be reduced. Accordingly, a scratch in a member clamping the metal gasket can be prevented and an excellent seal quality can be secured.
[0014] Also, in the metal gasket, the direction of top parts of the depressions and the projections of the surface pressure assistance plate is a direction intersecting with the half bead all around the half bead or a part of the perimeter of the half bead. With such a structure, the elastic effect due to the depressions and the projections of the surface pressure assistance plate can be used more efficiently than the structure in which the direction of the top parts of the depressions and the projections is arranged parallel to the half bead.
[0015] The depressions and the projections of the surface pressure assistance plate may be formed as a straight line such as a trapezoid, or formed as a curved line such as a circular shape or a sine shape. Also, the depressions and the projections may be formed as one step or multiple steps, and may or may not be line-symmetric with respect to the thickness direction. In addition, with respect to the perimeter direction of the seal target bore, the depressions and the projections may be formed in a continuous wave pattern and provided all around the seal target bore, or may be formed only in a part wherein a surface pressure adjustment is required. Also, shapes and sizes of the depressions and the projections may also be changed in the perimeter direction of the seal target bore according to the degree of the surface pressure adjustment. Moreover, the surface pressure adjustment plate itself may be disposed all around the seal target bore, or may be disposed only in a part wherein the surface pressure adjustment is required.
[0016] Detailed structures of the half bead part of the metal gasket are as follows. In the first structure, a first metal plate and a second metal plate which respectively form the half beads surrounding the seal target bore and expanding outside in a direction away from the seal target bore, are symmetrically disposed, and clamp a middle plate inside flat parts on the inner perimeter side (seal target bore side of half beads). Also, a surface pressure assistance plate, forming the depressions and the projections with respect to the thickness direction, is disposed on the outer perimeter side of the middle plate and inside the half beads between sloping parts of the half beads and flat parts on the outer perimeter side of the sloping parts. In the second structure, the middle plate and the surface pressure assistance plate are formed by the same plate of the first structure. In the third structure, the middle plate is eliminated, and the flat parts on the inner perimeter sides of the half beads of the first metal plate and the second metal plate are abutted against each other in the first structure.
[0017] In the fourth structure, the first metal plate forming the half bead surrounding the seal target bore and expanding outside in the direction away from the seal target bore; the middle plate disposed inside the flat part on the inner perimeter side of the half bead; the surface pressure assistance plate forming the depressions and the projections which are disposed on the outer perimeter side and inside the half bead between the sloping part of the half bead and the flat part on the outer perimeter side of the sloping part; and the flat second metal plate, are laminated. In the fifth structure, the middle plate and the surface pressure assistance plate are formed by the same plate in the fourth structure.
[0018] Moreover, instead of disposing the surface pressure assistance plate between the sloping part and the flat part of the half bead, the surface pressure assistance plate may be disposed on the outer perimeter side of the sloping part and inside the flat part on the outer perimeter side of the half bead. In this case, the surface pressure moderation effect on the corner part of the half bead is somewhat little. However, the elasticity of the half bead can be increased by the elasticity of the surface pressure assistance plate, so that it is expected that the creep relaxation be prevented.
[0019] Also, a metal gasket in which the present invention can be applied includes a metal gasket such as a gasket for an exhaust manifold for an engine, or a cylinder head gasket. These metal gaskets can have the above-mentioned large effect. However, the metal gasket is not limited to the above-mentioned gaskets, and may only be a metal gasket sealing the seal target bore.
[0020] According to the metal gasket of the present invention, the creep relaxation in the half bead around the seal target bore of the metal gasket can be prevented, and a scratch of a member clamping the metal gasket can be prevented by widening the distribution of the surface pressure generated in the half bead, so that an excellent seal quality can be secured.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 is a schematic plan view of a metal gasket according to an embodiment of the present invention;
[0022] FIG. 2 is a schematic plan view showing a state without a first metal plate in FIG. 1 of the metal gasket according to the first embodiment;
[0023] FIG. 3 is a schematic sectional view taken along line 3 - 3 in FIG. 1 of the metal gasket according to the first embodiment;
[0024] FIG. 4 is a schematic sectional view taken along line 4 - 4 in FIG. 1 of the metal gasket according to the first embodiment;
[0025] FIG. 5 is a schematic sectional view similar to FIG. 4 when the metal gasket is compressed;
[0026] FIG. 6 is a schematic plan view showing an example of a direction of top parts of depressions and projections of a surface pressure assistance plate;
[0027] FIG. 7 is a schematic plan view of another example of a direction of the top parts of the depressions and the projections of the surface pressure assistance plate;
[0028] FIG. 8 is a schematic sectional view, similar to FIG. 3 , of the metal gasket according to the second embodiment;
[0029] FIG. 9 is a schematic fragmentary perspective view of the metal gasket according to the second embodiment;
[0030] FIG. 10 is a schematic sectional view, similar to FIG. 3 , of the metal gasket according to the third embodiment;
[0031] FIG. 11 is a schematic sectional view, similar to FIG. 3 , of the metal gasket according to the fourth embodiment;
[0032] FIG. 12 is a schematic fragmentary perspective view of the metal gasket according to the fourth embodiment;
[0033] FIG. 13 is a schematic sectional view, similar to FIG. 3 , of the metal gasket according to the fifth embodiment;
[0034] FIG. 14 is a schematic fragmentary perspective view of the metal gasket according to the fifth embodiment;
[0035] FIG. 15 is a schematic view of a first example of depressions and projections of a surface pressure adjustment plate;
[0036] FIG. 16 is a schematic view of a second example of the depressions and the projections of the surface pressure adjustment plate;
[0037] FIG. 17 is a schematic view of a third example of the depressions and the projections of the surface pressure adjustment plate;
[0038] FIG. 18 is a schematic view of a fourth example of the depressions and the projections of the surface pressure adjustment plate;
[0039] FIG. 19 is a schematic view of a fifth example of the depressions and the projections of the surface pressure adjustment plate;
[0040] FIG. 20 is a schematic sectional view, similar to FIG. 3 , of the metal gasket according to the first embodiment with a different position of the surface pressure adjustment plate;
[0041] FIG. 21 is a schematic sectional view, similar to FIG. 3 , of the metal gasket according to the second embodiment with the different position of the surface pressure adjustment plate;
[0042] FIG. 22 is a schematic sectional view, similar to FIG. 3 , of the metal gasket according to the third embodiment with the different position of the surface pressure adjustment plate;
[0043] FIG. 23 is a schematic sectional view, similar to FIG. 3 , of the metal gasket according to the fourth embodiment with the different position of the surface pressure adjustment plate; and
[0044] FIG. 24 is a schematic sectional view, similar to FIG. 3 , of the metal gasket according to the fifth embodiment with the different position of the surface pressure adjustment plate.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0045] Hereunder, a metal gasket according to embodiments of the present invention will be explained with reference to the attached drawings.
[0046] Incidentally, FIGS. 1-24 are schematic explanatory views in which sizes of a seal target bore, bolt holes and half beads; widths of a middle plate and a surface pressure assistance plate; and thicknesses of a metal plate, middle plate and the surface pressure assistance plate; and sizes of depressions and projections are different from actual ones and enlarged for the sake of explanation. Also, for the sake of simplicity, hereunder, the seal target bore will be explained as one seal target bore. However, the present invention can be applied even when multiple kinds of seal target bores such as gas circulation holes, combustion chamber holes (bore holes), water holes, or oil holes, are respectively provided with multiple numbers, such as a gasket for an exhaust manifold for a multiple cylinder engine or a cylinder head gasket. Incidentally, the following “outside” and “inside” are terms with respect to a thickness direction of the gasket, and the horizontal direction of the gasket is described as an “outer perimeter side” and an “inner perimeter side”.
[0047] As shown in FIG. 1 , the metal gasket 1 of the embodiments of the present invention is formed of multiple metal plates (metal composition plates) made of soft steel, annealed stainless (annealed material), or stainless material (spring steel). Also, the metal gasket 1 is produced in a shape corresponding to the shape of a member clamping the metal gasket 1 , and is provided with a seal target bore 2 and bolt holes 3 for inserting tightening bolts.
[0048] In the first embodiment shown in FIGS. 1-5 , this metal gasket 1 has a first metal plate 10 and a second metal plate 20 arranged symmetrically, which clamp a middle plate 40 . Also, a surface pressure assistance plate 30 forming depressions and projections with respect to a thickness direction of the metal gasket 1 , is disposed on the outer perimeter side of the middle plate 40 , and inside between sloping parts 11 b, 21 b of half beads 11 , 21 and flat parts 11 c, 21 c on the outer perimeter side. More specifically, an inner perimeter side end of the surface pressure assistance plate 30 is disposed inside the sloping parts 11 b, 21 b.
[0049] For example, the first metal plate 10 and the second metal plate 20 are made of soft steel or annealed stainless (annealed material), and provided with the seal target bore 2 and the bolt holes 3 surrounding the seal target bore 2 . Also, the first metal plate 10 and the second metal plate 20 respectively provide the half beads 11 , 21 surrounding the seal target bore 2 and extending outside with respect to the thickness direction of the gasket in a direction away from the seal target bore 2 . Also, the first metal plate 10 and the second metal plate 20 are symmetrically disposed clamping the middle plate 40 .
[0050] The middle plate 40 is made of soft steel, annealed stainless (annealed material), or stainless material (spring steel), and as shown in FIG. 2 , disposed in a ring shape (circularity) around the seal target bore 2 . As shown in FIG. 3 , an inner perimeter side end 40 a facing the seal target bore 2 is arranged inside flat parts 11 a, 21 a on the inner perimeter side (seal target bore 2 side) of the half beads 11 , 21 . The middle plate 40 prevents liquid from entering between the half beads 11 , 21 and adjusts a thickness. Therefore, the middle plate 40 is formed in a sheet of ring-shaped continuous plate in a circumferential direction.
[0051] As shown in FIG. 2 , the surface pressure assistance plate 30 is disposed in a ring shape, and as shown in FIGS. 4 , 5 , forms the depressions and the projections with respect to the thickness direction. The surface pressure assistance plate 30 has elasticity relative to a compressive direction of the half beads 11 , 21 of the metal gasket 1 . When the half beads 11 , 21 are compressed, as shown in FIG. 5 , the surface pressure assistance plate 30 abuts against the sloping parts 11 b, 21 b of the half beads 11 , 21 , and provides a cushion effect, thereby adjusting the surface pressure of the half beads 11 , 21 .
[0052] The surface pressure assistance plate 30 is made of stainless material (spring steel) and the like, and as shown in FIGS. 4 , 12 , 15 , 16 , the depressions and the projections may be formed with straight lines such as a trapezoid. However, as shown in FIGS. 9 , 14 , 17 , 18 , 19 , the depressions and the projections may be formed with curved lines such as a circular shape or a sine shape. In addition, as shown in FIGS. 4 , 5 , 9 , 12 , 14 , 15 , 17 , 18 , the depressions and the projections may be formed by a single step, or as shown in FIGS. 16 , 19 , formed by multiple steps. Moreover, the depressions and the projections may or may not be axisymmetric with respect to the thickness direction.
[0053] Also, with respect to the perimeter direction of the seal target bore 2 , the depressions and the projections may be formed in a continuous wave pattern and provided all around the seal target bore 2 , or may be formed in a continuous wave pattern; a single projection; or a single depression, and the depressions and the projections may be formed in only a part wherein a surface pressure adjustment is required. Also, shapes and sizes of the depressions and the projections may also be changed according to the degree of the surface pressure adjustment. Moreover, the surface pressure assistance plate 30 itself may be disposed all around the seal target bore 2 , or may be disposed only in the part wherein the surface pressure adjustment is required. Basically, the depressions and the projections need only to have appropriate elasticity relative to the compressive direction of the metal gasket not to cause creep relaxation. The depressions and the projections can be easily formed by a pressing process and the like.
[0054] Also, as shown in FIG. 6 , the direction of top parts 30 a of the depressions and the projections of the surface pressure assistance plate 30 is a direction intersecting with the half beads 11 , 21 , preferably, 80-100°, more preferably, 90° (perpendicular), so that an elastic effect by the depressions and the projections of the surface pressure assistance plate 30 can be used more efficiently compared to the case of arranging the top parts of the depressions and the projections parallel to the half beads 11 , 21 . Also, when the top parts of the depressions and the projections are arranged in the intersecting direction, very narrow (linear) hit of corner parts of the half beads 11 , 21 can be made wide (planar) hit by abutting the depressions and the projections of the surface pressure assistance plate 30 against the slop parts 11 b, 21 b of the half beads 11 , 21 , so that the local surface pressure can be decreased. As a result, an abutting part in a member in which the half beads 11 , 21 abut, can be prevented from being scratched.
[0055] Incidentally, as shown in FIG. 7 , in the surface pressure assistance plate 30 , when the direction of the top parts 30 a of the depressions and the projections is made in one direction, an evenly spread surface pressure cannot be achieved as compared to the case wherein the top parts 30 a of the depressions and the projections are arranged in the direction intersecting with the half beads 11 , 21 . However, in this case, since the depressions and the projections are simplified, they can be produced more easily.
[0056] With respect to the arrangement of the intersecting direction, the surface pressure adjustment changes even by an intersecting angle, so that if the intersecting angle is changed by a required compressive elasticity (spring force), a precise surface pressure adjustment can be achieved. More specifically, in a part of perimeters of the half beads 11 , 21 , or all around the half beads 11 , 21 , the direction of the top parts of the depressions and the projections of the surface pressure assistance plate 30 is the direction intersecting with the half beads 11 , 21 . When the direction of the top parts of the depressions and the projections of the surface pressure assistance plate 30 is the direction intersecting with the half beads 11 , 21 all around the half beads 11 , 21 , for example, when the seal target bore 2 is a circle, the top parts (valleys and mountains) of the depressions and the projections are arranged radially.
[0057] Also, the surface pressure assistance plate 30 may be formed as a continuous ring in a perimeter direction of the seal target bore 2 . However, since the function is to adjust the surface pressure, the surface pressure assistance plate 30 does not necessarily need to be provided in a continuous integral part all around the perimeter direction, and divided multiple layers of surface pressure assistance plates 30 may be arranged to contact each other, or may be disposed separately only in parts wherein the surface pressure adjustment is required. More specifically, in the part of the perimeter of the half beads 11 , 21 or all around the half beads 11 , 21 , the surface pressure assistance plates 30 forming the depressions and the projections with respect to the thickness direction are disposed inside the half beads 11 , 21 .
[0058] According to the structure, the degree of the surface pressure adjustment can be changed with or without the surface pressure assistance plate 30 , by changes of shape and size (height, width and so on) of the depressions and the projections, a length of the top parts of the depressions and the projections (width of the surface pressure assistance plate 30 ), or an intersecting angle between the direction of the top parts of the depressions and the projections and the half beads 11 , 21 . Accordingly, the surface pressure can be easily adjusted very precisely.
[0059] As shown in FIGS. 8 , 9 , the metal gasket according to the second embodiment of the invention differs from the metal gasket according to the first embodiment, because the middle plate 40 and the surface pressure assistance plate 30 are formed in one sheet of surface pressure assistance plate 30 . The other structure of the metal gasket of the second embodiment is the same as that of the metal gasket of the first embodiment. Incidentally, as shown in FIG. 9 , the surface pressure assistance plate 30 is made to be flat on the inner perimeter side, and forms curved depressions and projections on the outer perimeter side.
[0060] In the second embodiment, the same plate has both functions of the middle plate 40 which is required for a sealing effect and the surface pressure assistance plate 30 which is required for an elastic effect. Accordingly, a material cannot be used separately. However, the second embodiment can be produced more easily compared to the first embodiment because the middle plate 40 is eliminated and a width of the surface pressure assistance plate 30 increases.
[0061] As shown in FIG. 10 , the metal gasket according to the third embodiment of the invention differs from the metal gasket according to the first embodiment because the middle plate 40 is eliminated. The other structure of the third embodiment is the same as that of the metal gasket of the first embodiment. Due to such a structure, the seal quality cannot be improved by the middle plate 40 . However, the metal gasket of the third embodiment can reduce the weight and size, and be produced more easily than the metal gasket of the first embodiment.
[0062] As shown in FIGS. 11 , 12 , the metal gasket according to the fourth embodiment of the invention laminates the first metal plate 10 , forming the half bead 11 surrounding the seal target bore 2 and expanding outside in the direction away from the seal target bore 2 ; the middle plate 40 disposed on the inner perimeter side of the half bead 11 , i.e., inside the flat part 11 a on the seal target bore 2 side; the surface pressure assistance plate 30 forming the depressions and the projections and disposed on the outer perimeter side and inside the half bead 11 between the sloping part 11 b of the half bead 11 and the flat part 11 c on the outer perimeter side; and the flat second metal plate 20 . The metal gasket of the fourth embodiment differs from the metal gasket of the first embodiment, because the half bead 21 is not formed on the second metal plate 20 .
[0063] The metal gasket of the fourth embodiment is suitable for the case in which a compressive transformation quantity due to the bead is small as compared to the metal gasket of the first embodiment, thereby saving materials and reducing the weight and size. Also, the thickness of the gasket can be reduced.
[0064] As shown in FIGS. 13 , 14 , the metal gasket according to the fifth embodiment differs from the metal gasket according to the fourth embodiment, because the middle plate 40 and the surface pressure assistance plate 30 are formed by one sheet of surface pressure assistance plate 30 . The other structure of the metal gasket of the fifth embodiment is the same as that of the metal gasket of the fourth embodiment. Incidentally, in FIG. 14 , the depressions and the projections of the surface pressure assistance plate 30 are made to be flat on the inner perimeter side, and have curved projections only on one side of the half bead 11 side on the outer perimeter side.
[0065] Also, in FIGS. 20-24 , in the metal gasket according to the first-fifth embodiments, instead of disposing the surface pressure assistance plate 30 inside between the sloping part 11 b ( 21 b ) of the half bead 11 ( 21 ) and the flat part 11 c ( 21 c ) on the outer perimeter side, the surface pressure assistance plate 30 is disposed inside the flat part 11 c ( 21 c ) on the outer perimeter side of the half bead 11 ( 21 ). In this case, the surface pressure moderation effect on the corner part of the half bead 11 ( 21 ) is a little. However, the elasticity of the half bead 11 ( 21 ) can be enhanced by the elasticity of the surface pressure assistance plate 30 , so that a creep relaxation of the half bead 11 ( 21 ) can be prevented.
[0066] According to the metal gasket 1 with the above-mentioned structure, the surface pressure assistance plate 30 forming the depressions and the projections is disposed with respect to the thickness direction, so that a creep relaxation of the half bead can be prevented by using the elastic effect due to the depressions and the projections of the surface pressure assistance plate 30 . Also, the surface pressure generated in the half bead 11 ( 21 ), especially, a force generated in the corner part of the half bead 11 ( 21 ) can be eased, so that the member clamping the metal gasket 1 can be prevented from being scratched, thereby securing an excellent seal quality.
[0067] The disclosure of Japanese Patent Application No. 2006-136113, filed on May 16, 2006, is incorporated in the application.
[0068] While the invention has been explained with reference to the specific embodiments of the invention, the explanation is illustrative and the invention is limited only by the appended claims. | A metal gasket includes first and second metal plates laminated together to form the metal gasket, and having holes to be sealed. At least one of the first and second metal plates has a half bead surrounding the hole. A surface pressure assistance plate is located at least adjacent to the half bead between the first and second metal plates. The assistance plate has depressions and projections with respect to a thickness direction thereof in at least a peripheral part thereof. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit, under 35 U.S.C. §119(e) of U.S. Provisional patent application No. 60/517,783, filed on Nov. 6, 2003.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to the field of solid-state chemistry, and, specifically, to the synthesis of mixed metal oxide ceramics, including perovskites.
2. Description of the Related Technology
Relaxor lead magnesium niobate Pb(Mg 1/3 Nb 2/3 )O 3 (PMN) has been studied extensively because of its high dielectric constant and large electrostrictive coefficients. For example, 0.9PMN-0.1PT(PbTiO 3 ) relaxor ferroelectric is a good candidate for multi-layer ceramic capacitor applications due to its high dielectric constant at room temperature. A 0.65PMN-0.35PT solid solution is a good piezoelectric material for sensor and actuator applications. However single-phase perovskite PMN could not be obtained by the conventional solid oxide method because of the presence of the pyrochlore phase, a reaction product between Nb 2 O 5 and PbO. Swartz and Shrout first succeeded in eliminating the pyrochlore phase by developing the columbite method that involved two calcination steps:
MgO + Nb 2 O 5 → 1000 ° C . MgNb 2 O 6 , and ( 1 ) MgNb 2 O 6 + 3 PbO → 700 - 900 ° C . 3 Pb ( Mg 113 Nb 213 ) O 3 . ( 2 )
In the first calcination step, mixtures of Nb 2 O 5 and MgO were heated near 1000° C. to form the columbite phase, MgNb 2 O 6 . In the second calcination step, MgNb 2 O 6 was mixed with PbO and heat-treated. The perovskite phase began to appear near 700° C. and complete perovskite conversion occurred near 900° C. The two calcination temperatures may vary with a number of parameters such as reactivity of MgO, degree of mixing, and control of the PbO volatility. Nevertheless, two calcination steps were needed to prevent the direct contact between Nb 2 O 5 and PbO and, thus, the formation of the pyrochlore.
Other methods including sol-gel methods solution processes, soft mechanochemical pulverization, co-precipitation, thermal spray, and Mg(NO 3 ) 2 mixing have also been developed to prepare pyrochlore-free PMN-PT powders. These methods were based on the principle of improving the reactivity of MgO either by optimizing the powder characteristics including particle size, specific surface area, reactivity of raw materials such as Mg(OH) 2 or Mg(NO 3 ) 2 , or by using a high-energy milling method. A molten salt method has also been shown to produce single-phase perovskite PMN-PT powders. Of all the available methods, the columbite method is still the most widely used method in preparing lead-based relaxor ferroelectrics because of its less stringent requirements on the raw materials and the high reliability of the process. However, the columbite method requires two calcination steps, i.e., the formation of the columbite phase at around 1000° C. followed by the complete formation of the perovskite phase at 900° C.
Because of the presence of pyrochlore phase, PMN ceramics are sintered using perovskite PMN powders. The regular sintering temperature of PMN ceramics is around 1200° C. At this temperature, the lead loss is serious. This results in an imprecise composition and deterioration of the final properties. In addition, with such a high sintering temperature low-cost electrodes such as Ag and Cu cannot be used to produce multi-layer capacitors and multi-layer actuators.
Another disadvantage of the traditional columbite method is the requirement of multiple processing steps. The traditional columbite method requires three ball milling steps, two calcination steps and one sintering step to obtain the final PMN ceramics. A process employing all of these steps is cost-prohibitive.
Although PMN-PT solid solutions possesses the best properties among its class, the commonly used technology for making PMN-PT solid solutions requires multiple heat treatment steps and a temperature of 1200° C. for the final sintering step. The cost associated with the multiple processing steps and the cost of special electrode materials that can sustain the high sintering temperature make PMN-PT solutions uncompetitive in important applications such as for multi-layer capacitors and multi-layer actuators. Some methods were found to permit lower sintering temperatures. For example, by adding 5-21 wt % excess of PbO, the sintering temperature can be reduced to 950° C. Adding 1-4 at % of SrO permits use of a sintering temperature as low as 800° C.-900° C. Use of PMN powder made by the Mg(NO 3 ) 2 mixing method, allows the sintering temperature to be reduced to 900° C. These methods, however, only permit lowering of the sintering temperature, but they still require multiple processing steps that result in a prohibitively high production cost.
By directly compacting the columbite phase and PbO into a green-body and sintering, the columbite method could be reduced to requiring two ball milling steps, one calcinations step, and one sintering step. However, the sintering temperature had to be increased to 1250° C. Later, with the same method, the sintering temperature was able to be reduced to 1000° C. by sintering a mixture of very fine TiO 2 powder with more reactive (PbCO 3 ) 2 Pb(OH) 2 in an O 2 atmosphere. Although this method had the advantages that it required fewer processing steps than the columbite method, and that it lowered the sintering temperature to 1000° C., this process still required two ball-milling steps, one calcination step and one sintering step. In addition, this method suffers from the additional disadvantages that there are additional costs associated with the fabrication of the required nanosize TiO 2 powder and for the provision of the O 2 sintering atmosphere, which still makes this method cost-prohibitive.
U.S. Pat. No. 5,079,199 (Ochi et al.) proposes to solve the problem of liquid Pb 2 WO 5 formation during the production of lead magnesium tungstate by first reacting MgO with WO 3 to form MgWO 4 , mixing, pressing and reacting with PbO to form the desired product. In this manner, liquid Pb 2 WO 5 formation is prevented. Ochi et al. filters, dries and reacts the mixture of MgO with WO 3 at 750-1000° C. to form magnesium tungstate powder. Mixtures of the magnesium tungstate powder were made with PbO, NiO, Nb 2 O 5 , MgO and TiO 2 in a ball mill. Each mixture was then filtered, dried, and calcined at 750-850° C., a disk was made and the disk was sintered in air at 925-1050° C. for one hour. Ochi et al. also mentions that a similar process can be employed for the manufacture of ceramic compositions containing as the main component, one or more perovskite compounds such as lead magnesium niobate.
In summary, each of these methods either reduced the complexity of the columbite process or reduced the required sintering temperature. However, none of these methods solved both the cost problem and the problem that sintering must be carried out at a high sintering temperature.
Therefore, there remains a need for an improved and cost effective method for making perovskites, as well as other mixed metal oxide ceramics in order to make these materials competitive in the market place. Although the above methods address certain aspects of making perovskites, none have managed to create a truly cost effective method of making perovskites. Applicants have managed to create such a method by transforming the pyrochlore phase commonly found in perovskite production. In transforming this phase Applicants have been able to reduce the production of perovskite to a single-step, low temperature reactive sintering method. This method is also broadly applicable to the synthesis of other mixed metal oxide ceramics and need not be used solely for perovskites.
SUMMARY OF THE INVENTION
Accordingly, it is an object of certain embodiments of the invention to provide a low-temperature reactive sintering method for the production of ceramics containing mixed metal oxides.
According to a first aspect of the invention, a method of making a ceramic composition comprising a mixed metal compound is disclosed. The method has a step (a) of at least partially coating a metal oxide powder comprising a first metal, with a compound selected from the group consisting of metal hydroxides and metal oxides comprising a second metal to form an at least partially coated metal oxide powder. The method also has a step (b) of compacting the at least partially coated metal oxide powder with one or more coating compounds selected from the group consisting of metal compounds and metal compound precursors, to form a body, the metal compounds and metal compound precursors containing a third metal. The method also has the step of heating the body from step (b) to form a ceramic composition comprising a mixed metal compound.
These and other objects of the present invention will be apparent from the summary and detailed descriptions of the invention, which follow.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic of Mg(OH) 2 coated Nb 2 O 5 particles mixed with PbO particles.
FIG. 2 is a flow chart depicting the method.
FIG. 3 a shows an optical micrograph of the coated Nb 2 O 5 particles.
FIG. 3 b shows an optical micrograph of uncoated Nb 2 O 5 particles.
FIG. 4 shows a graph of the reaction route of the method used in Examples 1 and 2.
FIG. 5 show a graph the separated reaction and sintering route.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The term “mixed metal compound” as used herein refers to single-phase materials comprising cations of two or more metallic elements.
The term “binary metal oxide” as used herein refers to single-phase materials comprising oxygen anions and cations of two metallic elements. Analogously, the terms “ternary metal oxide” and “quaternary metal oxide” refer to single-phase materials comprising oxygen anions and cations of three or four metallic elements, respectively.
The term “metal” as used herein, alone or in combined form, e.g., metallic or metallo-, refers to elements that can form cations in aqueous solution.
In a first embodiment of the present invention, a method of synthesizing mixed metal oxide ceramics is provided. In general, the method requires contacting a metal-oxide powder with a metal hydroxide or oxide to form a mixed metal powder. In a preferred embodiment, the metal oxide powder is at least partially coated with a metal hydroxide or metal oxide layer during the contacting step. In the preferred embodiment it is a metal hydroxide, however it is possible to coat with another metal compound, such as a metal oxide. The product of the contacting step is then mixed with one or more metal compounds or metal compound precursors to produce a mixed metal oxide powder. This powder may then be pressed and sintered to form a ceramic containing a mixed metal oxide.
While not wishing to be bound by any particular theory, it is thought that the present approach provides at least a partial coating of the metal oxide powder precursor with the metal hydroxide or metal oxide. This reduces or prevents contact between the first metal compound and the second metal compound or second metal compound precursor to thereby reduce or substantially prevent the formation of undesirable products during the sintering step. Also, the provision of at least a partial coating on the metal compound starting material is found to enhance mixing between the reacted pyrochlore phase and the metal oxide by increasing the surface contact between them, thereby causing the perovskite transformation temperature to overlap with the sintering temperature during the sintering step used to produce a green body or ceramic. In addition, the partial coating appears to result in smaller particles during the reaction, which promotes sintering at lower temperatures.
The method can be applied, for example, to the production of lead magnesium niobate Pb(Mg 1/3 Nb 2/3 )O 3 (hereinafter “PMN”). In this method, low temperature processing of PMN can be achieved by virtue of the at least partial coating of Nb 2 O 5 powder with Mg(OH) 2 . The present method is based on the principle of the overlap of the perovskite formation temperature due to the intimate mixing of reaction ingredients and the lowered sintering temperature due to the smaller particle size of reacted phase. However, unlike the columbite method, only one final sintering step is needed in the present method. The at least partial coating of Mg(OH) 2 on Nb 2 O 5 is believed to increase the intimate mixing of the reacted pyrochlore phase with MgO, and, thus, this causes the perovskite formation temperature to overlap with the sintering temperature significantly. Furthermore, the mixing of the at least partial coating of Mg(OH) 2 on Nb 2 O 5 and PbO reduces the required reaction temperature and results in smaller pyrochlore particles, which promotes sintering at lower temperatures.
In a preferred embodiment Mg(OH) 2 is used as the coating material, however it is possible that another metal hydroxide, or metal oxide could be used in its place, such as, AlOOH, SiO 2 , TiO 2 , Ti(OH) 4 , ZnO, Zn(OH) 2 , ZrO 2 and Zr(OH) 4 . Also, the starting reactant for the method need not be limited to PbO, but may also include other metal compounds such as 3Pb(NO 3 ) 2 7PbO, Pb(NO 3 ) 2 , PbCO 3 , (PbCO 3 ) 2 Pb(OH) 2 and Pb(OH) 2 .
A method for the at least partial coating of Nb 2 O 5 with Mg(OH) 2 is described in the article, “Single-Calcination Synthesis of Pyrochlore-Free 0.9 Pb(Mg 1/3 Nb 2/3 )O 3 -0.1PbTiO 3 and Pb(Mg 1/3 Nb 2/3 )O 3 Ceramics Using a Coating Method,” Huiming Gu, Wan Y. Shih and Wei-Heng Shih, J. Am. Ceram. Soc., 86 [2] 217-221 (2003), the disclosure of which is hereby incorporated by reference.
More specifically, to provide at least a partial coating, Mg(NO 3 ) 2 6H 2 O may be dissolved in water followed by the addition of Nb 2 O 5 powder to the solution. The mixture may then be treated to break up the Nb 2 O 5 agglomerates and a hydroxide can be added to the mixture until the pH exceeds about 8.9, and more preferably, until the pH is in the range of 9-11, and most preferably, the pH is in the range of 9.5-10.5. The mixture may then be stirred for a sufficient time to form Mg(OH) 2 in situ and precipitate Mg(OH) 2 on the surface of the Nb 2 O 5 to thereby provide an at least partially coated Nb 2 O 5 powder product. The Mg(OH) 2 does not have to be formed in situ, but rather, can be directly introduced to the reaction, as long as it can be coated on the surface of Nb 2 O 5 . Typically, reaction times of 10 minutes to 2 hours are required for the precipitation reaction, and more preferably, the precipitation reaction takes about 15 minutes to 1 hour. The reaction may be allowed to proceed to provide substantially complete coating of the Nb 2 O 5 powder product.
Preferably, the Mg-containing precursor and the Nb containing precursor are used in amounts that provide approximately equimolar amounts of Mg and Nb. For example, the molar ratio of Mg to Nb in the reaction mixture is preferably from about 0.8-1.2, and more preferably from about 0.9-1.1.
The suspension of at least partially coated Nb 2 O 5 powder may then be mixed with, for example, a suspension of PbO, or a suspension of a mixture of PbO and PbTiO 3 , which is prepared by mixing distilled water, PbO and PbTiO 3 in the amounts required to give the desired ratio of PbO to PbTiO 3 . The mixture of the two suspensions may then be stirred to provide a substantially homogenous mixture and dried to provide a powder. The dried powder may then be compacted and sintered to produce a ceramic containing PMN in a substantially pure perovskite phase. The method of the present invention results in a substantially pure perovskite phase with only one sintering step, as schematically illustrated in FIG. 1 .
As shown in FIG. 2 , by compacting a mixture of Nb 2 O 5 at least partially coated with Mg(OH) 2 and PbO, or a mixture of PbO and PbTiO 3 powders into a green body, and performing a single heat treatment at 1000° C. for 2 hours, 0.9PMN-0.1PT ceramics of 94% theoretical density, with good dielectric properties are produced.
This method provides dense perovskite phase PMN-PT ceramics by sintering the compacts in a single heat treatment step. The powder mixture is preferably ball milled for mixing and compacting. Compacting is preferably carried out as a dry compacting step, although it may optionally be carried out in the presence of a conventional granulating fluid, such as polyvinyl alcohol. The dried compact is heated at 3° C./min to 500° C. and held for 1-3 hours. The compact is then heated to a temperature of from about 800° C. to about 1100° C. at 5° C./min and held there for about 1-3 hours. More preferably, the compact is heated to a temperature of from about 900° C. to about 1050° C. and held there for about 1.5-2.5 hours. Most preferably, the compact is heated to a temperature of about 1000° C. for a period of about 2 hours. The above steps can be performed with all (1−x)PMN-xPT solid solutions, with x varying from 0 to 1. The exact times and temperatures for the heating step may vary depending on the composition the compact.
As shown in FIG. 3 , at T<500° C. there is no reaction and no major density or particle size change. At temperatures of 500° C.-800° C. a pyrochlore phase is formed, this results in volume expansion and the particle size decreases. At temperatures of 800° C.−1000° C., the pyrochlore phase transforms to a perovskite phase and significant density and grain size increases are observed. Equal or larger than stoichiometric PbO content in the reaction mixture is required to obtain the grain size and density increases. Stoichiometric amounts of PbO will result in the best dielectric properties in the products. The grain size increases with increasing PbO content and saturates at 102% of PbO. Density peaks at 102% of PbO. Excess PbO beyond 102% is not harmful but may be undesirable from an economic standpoint.
The method produces a smaller pyrochlore phase and smaller MgO particles than the conventional columbite method. The powders are more homogeneously mixed by the reaction of the at least partially coated particles with the PbO particles.
The clear advantages of the present method are that it requires only one ball milling step and one sintering step at 1000° C., 200° C. lower than the traditional columbite method, and there are no special requirements for the raw materials and equipment. The lower sintering temperature even allows the use of less expensive metals for the electrodes than would be required for the conventional columbite process, and the simple streamlined process will provide dramatically lower costs, making this superior material economically competitive for many dielectric and piezoelectric applications including multi-layer capacitors and multi-layer actuators.
The preferred embodiment is disclosed above, but this method can be used for other combinations of materials, and is broadly applicable to the synthesis of mixed metal compounds in general. For example, at least partially coating metal compound particles with a metal hydroxide or oxide layer, and then sintering the particles, optionally together with other precursors, can produce other mixed metal compounds in an economically attractive process. The method is particularly effective for the synthesis of perovskites in systems that suffer from the problem of pyrochlore formation during sintering, similar to the of lead magnesium niobate (PMN) system described above.
Other perovskite systems that can be benefited by the method of the present invention, for example, are, lead magnesium tantalite, lead nickel niobate, lead scandium tantalite, barium titanate and lead indium niobate. The times and temperatures of the heating step may vary for these systems depending on the composition of the compact treated in the heating step.
The method can also be beneficial to the production of perovskites using sintering processes which do not suffer from the problem of pyrochlore formation since this direct sintering approach can potentially lower the sintering temperature of the system due to the more reactive nature of the at least partially coated metal oxide powders employed as a reactant in the process. For example, direct sintering of lead zirconate titanate (PZT) has been achieved by this method.
The following examples are provided to describe the invention in further detail. These examples, which set forth a preferred mode presently contemplated for carrying out the invention, are intended to illustrate and not to limit the invention.
EXAMPLE 1
This example demonstrates one step in the preferred embodiment of the instant invention that involves the creation of a coating of Mg(OH) 2 on Nb 2 O 5 .
Starting materials used in this preferred embodiment are Nb 2 O 5 (99.9%), PbTiO3 (99+%), PbO (99.9+%), Mg(NO 3 ) 2 .6H 2 O (99%), and NH 4 OH (5.08 N). The 0.9PMN-0.1 PT and PMN precursors are prepared in the following manner. Mg(NO 3 ) 2 .6H 2 O (0.105 mol) is dissolved in 500 mL of distilled water, followed by the addition of 0.1 mol of Nb 2 O 5 powder to the solution. This mixture is denoted as suspension I.
Suspension I, is then stirred and ultrasonicated (50 MHz, 50 W) for 10 min. to break up the Nb 2 O 5 agglomerates. At this point, the suspension pH will be between 5 and 6. For Mg(OH) 2 to precipitate on the Nb 2 O 5 surface, NH 4 OH (5.08N) is added dropwise into the mixture until the pH reaches 10. The mixture is then stirred for 30 minutes.
The surface of Nb 2 O 5 is negatively charged at pH>6, and is attracted to the Mg 2+ ions. This promotes the precipitation of Mg(OH) 2 on the Nb 2 O 5 , making the coating of Mg(OH) 2 on Nb 2 O 5 possible. This procedure performed in the preferred embodiment will produce a coating of Mg(OH) 2 on Nb 2 O 5 . This coating is advantageous in making the powders more reactive and transforming the pyrochlore phase into perovskites. The formation of the coating can also be advantageous in preventing other reagents from reacting with one another in different metal compound systems.
EXAMPLE 2
This example demonstrates the direct sintering process of the present invention.
First, the product of Example 1 is mixed with a suspension of PbO and PbTiO 3 , which is denoted as suspension II. Suspension II is prepared by mixing 200 mL of distilled water with 0.303 mol of PbO and an appropriate amount of PbTiO 3 , depending on the desired composition of the PMN-PT solid solution. Suspension II is ultrasonicated for 10 minutes before it is added to the product of Example 1. The mixture then is stirred for 60 minutes and dried by rotary evaporation. The dried powders are ball-milled in isopropyl alcohol for 20 hours and rotary evaporated. It is to be understood that although ball-milling is used in the example provided, alternative methods are available which can be used in the present invention, such as, high-energy ball-milling, Jet Pulverizers, and Pulverizing Mills.
The mixture of Mg(OH) 2 -coated Nb 2 O 5 , PbO and PbTiO 3 powders is then used to create a green body. This green body is created by pressing the powders at 200 MPa into pellets 1 mm thick and 25 mm in diameter.
The green body is then used in the sintering process. The dried compact is heated at 3° C./min to 500° C. and held for 2 hr. The sample is then heated to 1000° C. at 5° C./min and held there for 2 hr. This process produces a dielectric ceramic containing 0.9PMN-0.1PT and having a 93.6% theoretical density, with good dielectric properties.
The process disclosed in the example is more efficient than previous methods. Furthermore, the process set forth in this example can be made applicable to other mixtures.
EXAMPLE 3
An optical micrograph of the coated Nb 2 O 5 particles is shown in FIG. 3 a with the light colored Nb 2 O 5 particles surrounded by dark-colored coating layers. For comparison, an optical micrograph of uncoated Nb 2 O 5 particles is shown in FIG. 3 b to confirm that uncoated Nb 2 O 5 particles appear as light-colored particles. The dark-colored coating layer was shown to be Mg(OH) 2 by precipitating a powder of Mg(OH) 2 under the same precipitation conditions used to provide the coating, except in the absence of Nb 2 O 5 particles.
EXAMPLE 4 AND COMPARATIVE EXAMPLES A-E
The method of the present invention, as set forth in Examples 1-2 above was performed to produce a ceramic dielectric material comprising 0.9 Pb(Mg 1/3 Nb 2/3 )O 3 -0.1PbTiO 3 , with sintering using the “regular route” shown in FIG. 4 . In comparative example A, the conventional columbite route described above, was employed using the separated reaction and sintering route shown below to produce a ceramic dielectric material comprising 0.9 Pb(Mg 1/3 Nb 2/3 )O 3 -0.1PbTiO 3 . In comparative example B, the conventional columbite route was employed except that instead of separate reaction (calcining) and sintering steps, the materials were directly sintered in a single step using the regular route shown below to produce a ceramic dielectric material comprising 0.9 Pb(Mg 1/3 Nb 2/3 )O 3 -0.1PbTiO 3 . In comparative example C, the reactive columbite method of Y. C. Liou, L. Wu, and S. S. Liou, Jpn. J. Appl. Phys ., Vol. 33, Pt. 2, No. 9B (1994) was employed to produce a ceramic dielectric material comprising 0.9 Pb(Mg 1/3 Nb 2/3 )O 3 -0.1PbTiO 3 . In comparative example D, a modified version of the reactive columbite method as described in S. Kwon, E. M. Sabolsky, G. L. Messing, J. Am. Ceram. Soc., 84[3]648-650 (2001) was employed to produce a ceramic dielectric material comprising 0.9 Pb(Mg 1/3 Nb 2/3 )O 3 -0.1PbTiO 3 . In comparative example E, the coating method of the present invention was employed together with the separated reaction and sintering route shown in FIG. 5 to produce a ceramic dielectric material comprising 0.9 Pb(Mg 1/3 Nb 2/3 )O 3 -0.1PbTiO 3 . The results are shown in Table 1. The relative density was measured by the Archimedes method in kerosene.
TABLE 1
Example
Relative Density (%)
Example 4
93.6
Comparative Example A
89.2
Comparative Example B
88.7
Comparative Example C
60.9
Comparative Example D
70.1
Comparative Example E
76.2
EXAMPLE 5
This example demonstrates one step in an embodiment of the instant invention that involves the creation of a coating of zirconium hydroxide on TiO 2 (53% zirconia and 47% titania) and the direct sintering of PZT in the present invention.
Two grams of titania were dissolved in distilled water. Once the titania was dissolved, an appropriate amount of zirconyl nitrate solution (ZrO(NO 3 ) 2 was added to the solution and dissolved. Raising the pH to approximately 10 by adding ammonium hydroxide precipitated the zirconia. The mixture was then stirred for two hours, centrifuged, and washed several times with distilled water. The powders were then dried overnight.
The resulting zirconia-titania powders were mixed with a suspension of PbO with 10% wt. excess. The additional PbO was added to compensate for lead loss during sintering. The mixed powders were ball-milled in a plastic jar having alcohol as the solvent and containing zirconia balls. After ball-milling, the resulting slurry was dried to evaporate as much alcohol as possible. The resulting materials of the evaporated slurry were then ground into powder and mixed with a three percent aqueous polyvinyl alcohol (PVA) solution, which was used as a binder. Large lumps were sieved and ground again until they passed through the sieve. Removing large chunks of powder ensured better powder packing during compaction.
The powder was then dry-pressed using a one-inch diameter circular die. Four grams of the powder was pressed to form green-bodies. The pressure of the press was increased steadily until it reached approximately 5000 kg force and was held there for about one to two minutes before being slowly unloaded. The green bodies were heat treated at 600° C. for two hours to burn off the PVA binder. Then the samples were heat treated to 1000° C. at a rate of 5° C./min and held there for one hour.
The process employed in the above example is more efficient than processes using simple mixtures of zirconia, titania, and lead oxide. Not only is the density of the samples higher, but also the dielectric constant of the samples is superior to that achieved when using simple mixtures.
It is to be understood that even though numerous characteristics and advantages of the present invention have been set forth in the foregoing description, together with details of the method, the disclosure is illustrative only, and changes may be made within the principles of the invention to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed. | A method of making dielectric ceramics containing mixed metal oxides is provided. The method comprises the steps of at least partially coating a metal oxide powder with a metal hydroxide or metal oxide, compacting the coated powder with one or more additional metal compounds or metal compound precursors, and directly sintering the compact in a single step. The method of the invention may be used to avoid occurrence of significant quantities of one or more undesired but thermodynamically or kinetically favored side products. The method of the invention may also be used to synthesize perovskites, in particular lead-magnesium-niobium (PMN), lead-magnesium-niobium-lead-titanium (PMN-PT) perovskites, or lead zirconate titanate (PZT). | 2 |
RELATED APPLICATION
This application is a continuation of U.S. patent application Ser. No. 09/107,063, filed Jun. 30, 1998, which is incorporated herein by reference in its entirety. That application is a divisional of U.S. patent application Ser. No. 08/660,087, filed Jun. 3, 1996, now U.S. Pat. No. 5,896,444 issued Apr. 20, 1999, which is also incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
1. The Field of the Invention
The present invention pertains to the field of client-server computer networking. More particularly, the present invention relates to a method and apparatus for providing communications between a client and a server in a computer network.
2. The Prior State of the Art
The number of homes and businesses using personal computers has increased substantially in recent years. Along with this increase has come an explosion in the use of the Internet, and particularly in the use of the World-Wide Web (“the Web”). The Web is a collection of formatted hypertext pages located on numerous computers around the world that are logically connected by the Internet. Advances in network technology, particularly software for providing user interfaces to the Web (“Web browsers”), have made the Web accessible to a large segment of the population. However, despite the growth in the development and use of the Web, many people are still unable to take advantage of this important resource.
Access to the Web has thus far been limited mostly to people who have access to a personal computer. However, many people cannot afford the cost of even a relatively inexpensive personal computer, while others are either unable or unwilling to learn the basic computer skills that are required to access the Web. Furthermore, Web browsers in the prior art generally do not provide the degree of user-friendliness desired by some people, and many computer novices do not have the patience to learn how to use the software. Therefore, it would be desirable to provide an inexpensive means by which a person can access the Web without the use of a personal computer. In particular, it would be desirable for a person to be able to access the Web pages using an ordinary television set and a remote control, so that the person feels more as if he or she is simply changing television channels, rather than utilizing a complex computer network.
Computer systems often communicate data with each other over large distances using standard telephone lines (also known as “POTS,” for Plain Old Telephone Service). Often a computer does not have a telephone line dedicated solely for its own use, however. Instead, a computer often uses a telephone line that is also used for standard telephone voice communication. Such dual use of the telephone line can cause problems for computers. For example, many conventional telephone services provide a feature known as “Call Waiting,” which notifies a person involved in a telephone conversation when there is another incoming call on that line. The person receiving the new call generally is notified by an audible tone caused by a Call Waiting signal. In response, the person can either switch to the other call without disconnecting the call already in progress (a technique sometimes called “flashing”) or simply ignore the new call. However, a Call Waiting signal can severely disrupt data communications if it is received while a computer is using the line.
Although some communications software provides the ability to disable the Call Waiting signal, doing so has the disadvantage that the computer's user generally has no way of knowing when someone is trying to reach him by telephone. Hence, it would be desirable to avoid severe disruptions without disabling the Call Waiting capability, particularly when browsing the Web.
Prior art systems that have accommodated Call Waiting during modem communications have done so only in client-to-client communications, and have only handled the case of both clients and modems being programmed to handle a Call Waiting interruption. Examples of such systems are a voice-over-data modem designed by Phylon, Inc., of Fremont, Calif., and a data-only modem designed by Catapult Entertainment of Cupertino, Calif. Both products are designed for video game play over a modem, and both handle Call Waiting interruptions by detecting the interruption, signaling the other client of the condition, and then both clients terminating the phone connection to allow the incoming call to be answered. When the call is completed, one modem dials the other to resume game play.
These two systems do not handle a more difficult condition: that of a client modem that is designed to handle a Call Waiting interruption which is dialed into a server modem that is not. For example, such a client modem might dial into a modem pool, such as that providing Internet access, which was designed using conventional modems. Since such conventional modems were designed with the assumption that dial-up would be through a phone connection that was not to be periodically interrupted by Call Waiting, they do not support the signaling and reconnect protocols that allowed the prior art video game modems to resume a connection smoothly after a Call Waiting interruption.
Unfortunately, the vast majority of server modems in use in the world today are conventional modems designed with the assumption that the dial-up is through a connection not periodically interrupted by Call Waiting. Thus, as a practical matter, the prior art video game modems, which rely on the system on the other side of the phone connection as including a Call Waiting aware modem and client, do not handle a client-server modem connection that is interrupted by Call Waiting.
In addition to the Call Waiting feature, some telephone services provide a feature known as Caller ID. Caller ID provides a person who receives a telephone call and who has the proper equipment with the phone number from which an incoming call originates. This service can be quite useful when the person receiving the call recognizes the number. However, people sometimes receive telephone calls originating from telephone numbers with which they are not familiar. Therefore, it would be desirable to provide a Caller ID subscriber with more detailed information regarding the source of an incoming call. It would further be desirable to provide such information to a subscriber who is using the telephone line to browse the Web at the time the call is received.
SUMMARY AND OBJECTS OF THE INVENTION
In a client system communicating with a server system over a communication link, a method is provided of responding to a disruption in communication with the server system. The communication link includes a telephone line. In response to the disruption, the client system saves the browsing status and terminates communication with the server system. The client system later reconnects to the server system and established the same browsing status as existed at the time of the disruption.
Other features of the present invention will be apparent from the accompanying drawings and from the detailed description which follows.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention is illustrated by way of example and not limitation in the figures of the accompanying drawings, in which like references indicate similar elements and in which:
FIG. 1 illustrates several client systems connected to a server system in a network.
FIG. 2A illustrates a client system for browsing the World-Wide Web.
FIG. 2B is a block diagram of an electronics unit of the client system.
FIG. 3 illustrates telephones, a client system, and a standard personal computer sharing one telephone line.
FIG. 4 illustrates the functional relationship between hardware and software in the client system.
FIG. 5 is a flow diagram illustrating a routine for handling an interruption in communication in the client system.
FIG. 6 is a flow diagram illustrating a routine for responding to a call-waiting signal.
FIG. 7 is a flow diagram illustrating a routine for determining a name associated with a phone number derived from Caller ID information.
FIG. 8 is a flow diagram illustrating a routine used by a client system for selectively notifying a user of an incoming telephone call.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A method and apparatus are described for managing communications between a client and a server in a computer network. In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It will be evident, however, to one skilled in the art that the present invention may be practiced without these specific details. In other instances, well-known structures and devices are shown in block diagram form in order to avoid unnecessarily obscuring the present invention.
The present invention includes various steps, which will be described below. The steps can be embodied in machine-executable instructions, which can be used to cause a general-purpose or special-purpose processor programmed with the instructions to perform the steps. Alternatively, the steps of the present invention might be performed by specific hardware components that contain hardwired logic for performing the steps, or by any combination of programmed computer components and custom hardware components.
The present invention is included in a system, known as WebTV™, for providing a user with access to the Internet. A user of a WebTV™ client generally accesses a WebTV™ server via a direct-dial telephone (POTS, for “plain old telephone service”), ISDN (Integrated Services Digital Network), or other similar connection, in order to browse the Web, send and receive electronic mail (e-mail), and use various other WebTV™ network services. In the preferred embodiment, the WebTV™ network services are provided by WebTV™ servers using software residing within the WebTV™ servers in conjunction with software residing within a WebTV™ client.
FIG. 1 illustrates a basic configuration of the WebTV™ network according to one embodiment. A number of WebTV™ clients 1 are coupled to a modem pool 2 via direct-dial, bi-directional data connections 29 , which may be telephone (POTS, i.e., “plain old telephone service”), ISDN (Integrated Services Digital Network), or any other similar type of connection. The modem pool 2 is coupled typically through a router, such as that conventionally known in the art, to a number of remote servers 4 via a conventional network infrastructure 3 , such as the Internet. The WebTV™ system also includes a WebTV™ server 5 , which specifically supports the WebTV™ clients 1 . The WebTV™ clients 1 each have a connection to the WebTV™ server 5 either directly or through the modem pool 2 and the Internet 3 . Note that the modem pool 2 is a conventional modem pool, such as those found today throughout the world providing access to the Internet and private networks.
Note that in this description, in order to facilitate explanation the WebTV™ server 5 is generally discussed as if it were a single device, and functions provided by the WebTV™ services are generally discussed as being performed by such single device. However, the WebTV™ server 5 may actually comprise multiple physical and logical devices connected in a distributed architecture, and the various functions discussed below which are provided by the WebTV™ services may actually be distributed among multiple WebTV™ server devices.
FIG. 2A illustrates a WebTV™ client 1 . The WebTV™ client 1 includes an electronics unit 10 (hereinafter referred to as “the WebTV™ box 10 ”), an ordinary television set 12 , and a remote control 11 . In an alternative embodiment of the present invention, the WebTV™ box 10 is built into the television set 12 as an integral unit. The WebTV™ box 10 includes hardware and software for providing the user with a graphical user interface, by which the user can access the WebTV™ network services, browse the Web, send e-mail, and otherwise access the Internet.
The WebTV™ client 1 uses the television set 12 as a display device. The WebTV™ box 10 is coupled to the television set 12 by a video link 6 . The video link 6 is an RF (radio frequency), S-video, composite video, or other equivalent form of video link. The communication link 29 between the WebTV™ box 10 and the server 5 is either a telephone (POTS) connection 29 a or an ISDN connection 29 b . The WebTV™ box 10 receives AC (alternating current) power through an AC power line 7 .
Remote control 11 is operated by the user in order to control the WebTV™ client 1 in browsing the Web, sending e-mail, and performing other Internet-related functions. The WebTV™ box 10 receives commands from remote control 11 via an infrared (IR) communication link. In alternative embodiments, the link between the remote control 11 and the WebTV™ box 10 may be RF or any equivalent mode of transmission.
FIG. 2B is a block diagram of the internal features of the WebTV™ box 10 . Operation of the WebTV™ client 1 is controlled by a central processing unit (CPU) 21 which is coupled to an Application-Specific Integrated Circuit (ASIC) 20 . The CPU 21 executes software designed to implement features of the present invention. ASIC 20 contains circuitry which may be used to implement certain features provided by the WebTV™ client 1 . ASIC 20 is coupled to an audio digital-to-analog converter 25 which provides audio output to television 12 . In addition, ASIC 20 is coupled to a video encoder 26 which provides video output to television set 12 . An IR interface 24 detects IR signals transmitted by remote control 11 and, in response, provides corresponding electrical signals to ASIC 20 . A standard telephone modem 27 and an ISDN modem 30 are coupled to ASIC 20 to provide connections 29 a and 29 b , respectively, to the modem pool 2 and, via the Internet 3 , to the remote servers 4 . Note that the WebTV™ box 10 also may include a cable television modem (not shown).
Also coupled to ASIC 20 is Read-Only Memory (ROM) 22 , which provides storage of program code for implementing the application software to be executed by the WebTV™ box 10 . Note that ROM 22 may be a programmable ROM (PROM) or any form of erasable PROM (EPROM) or Flash memory. Also coupled to ASIC 20 is Random Access Memory (RAM) 23 . A mass storage device 28 may optionally be provided and coupled to ASIC 20 . The mass storage device 28 may be used to input software or data to the client or to download software of data received over network connection 29 . The mass storage device 28 includes any suitable medium for storing machine-executable instructions, such as magnetic disks, optical disks, and the like.
FIG. 3 illustrates a WebTV™ client 1 implemented in a home 15 according to one exemplary embodiment. Within the home 15 , the WebTV™ client 1 shares the telephone line 29 a with two conventional telephone sets (“extensions”) 10 and a modem of a personal computer 12 . Accordingly, the telephone line 29 a is used for both data communication (by WebTV™ client 1 and the personal computer 12 ) and voice communication at different times. The telephone line 29 a corresponds to a single telephone number within the home 15 .
As mentioned above, the WebTV™ box 10 includes application software including a Web browser. Referring now to FIG. 2A, the above-mentioned application software 31 operates in conjunction with operating system (OS) software 32 . The OS software 32 includes various device drivers and otherwise provides an interface between the application software 31 and the system hardware components 40 (i.e., the elements illustrated in FIG. 1 C).
In the preferred embodiment, the application software 31 and OS software 32 are generally stored in ROM 22 . It will be recognized, however, that either or both of application software 31 and OS software 32 can be stored on any suitable storage medium, including magnetic or optical storage devices.
Assume now that the WebTV™ client 1 is implemented in a configuration as shown in FIG. 3 . That is, the WebTV™ client 1 shares a single telephone line 29 a with one or more standard telephone extensions in a home 15 . Assume further that telephone service provided to the home 15 includes the Call Waiting and Caller ID services. Hence, an incoming telephone call received at the home 15 while the user is browsing the Web using the WebTV™ client 1 will be indicated by reception of a Call Waiting signal. The Call Waiting signal will cause disruptions in data communications on the telephone line. Some prior art client-to-server modems treat a disruption such as a Call Waiting signal as an error condition and either attempt to maintain the data connection or simply lose the connection. Other prior art client-to-server modems simply disable the Call Waiting signal. A disadvantage of both of these approaches is that the user of the Web browser is typically left unaware of the incoming call. The present invention, however, overcomes this disadvantage.
Any interruption in data communication is essentially treated as a pause condition by the WebTV™ client 1 . Specifically, in response to any interruption in data communication, including a Call Waiting signal, the client 1 automatically disconnects from the modem pool 2 and then automatically reconnects to the modem pool 2 at a later time while maintaining the user's browsing state. Referring now to FIG. 5, if an interruption in communication is detected by the WebTV™ client 1 (step 501 ) while the client 1 is in contact with the WebTV™ server 5 (or any other server), then the client 1 saves information describing the current browsing status to memory (RAM) 23 (step 502 ). The saved information includes all information that is necessary to exactly identify the Web site at which the user was browsing and to automatically return to that location later without further input from the user. Once the status information is saved, the client 1 automatically disconnects from the modem pool 2 (step 503 ). The client 1 then waits for a predetermined time interval T 1 (ten seconds, for example) (step 504 ). At the expiration of the time interval T 1 , the client 1 determines whether an incoming call is still being received by attempting to detect a ring signal on the telephone line 29 (step 505 ). Detection of a ring signal would indicate that a third party is still attempting to call in, since an on-hook condition after a Call Waiting signal tells the Telephone Company Central Office telephone switch that it is to transmit a ring signal. The client 1 further determines whether all telephone extensions are on the hook (i.e., inactive, or closed) (step 506 ). This determination is made by sensing the impedance on the telephone line 29 . If no ring signal is detected and all extensions are on the hook, then the client 1 automatically redials the modem pool 2 and resumes the previous browsing state based the status information saved earlier (step 507 ). If, however, either a ring signal is detected or an extension is off the hook (active) (e.g., if another member of the household had picked up an extension phone and had begun to dial), then the client 1 waits until that is not the case before re-establishing the connection to the modem pool 2 . Thus, whether the disruption was a Call Waiting interruption or a disruption from another person trying to make a call, the same mechanism gracefully handles the situation.
As mentioned above, it is assumed that the telephone service provided to the home 15 includes Caller ID service. Note, however, that Caller ID service is not essential to support the Call Waiting capabilities of the present invention. The present invention utilizes the Caller ID information to provide the user with information identifying the source of the incoming call. Referring now to FIG. 6, assume that an incoming telephone call is received while the user is browsing the Web. Accordingly, the client 1 disconnects from the modem pool 2 after saving browsing status information. The client 1 then causes a message to be displayed to the user on the television set 12 indicating that an incoming call is being received (step 601 ). The client then waits for Caller ID information. This information is typically is received between the first and second ring signal (step 601 ). If Caller ID information is received before the expiration of a preset time period, such as before the second ring signal (step 602 ), then the client 1 determines whether the phone number of the incoming call has previously been stored in memory 23 with a corresponding name (step 603 ). If so, the name corresponding to the source of the incoming call is retrieved from memory 23 and displayed to the user in conjunction with the Call Waiting message (step 604 ). If no Caller ID information is received or if there is no name corresponding to the incoming phone number stored in memory 23 , then a message is displayed to the user indicating that the name of the caller is unknown (step 608 ). If the user accepts the incoming call by picking up one of the telephone sets 10 within the predetermined number of rings, the routine ends (step 605 ). However, if the user does not accept the call, client 1 automatically answers the call. Specifically, the client 1 plays a recorded greeting to the caller (step 606 ) and then digitally records any message the incoming caller chooses to leave (step 607 ). The message left by the incoming caller is also played to the user of the client 1 in real time as it is recorded, using the speaker of the television set 12 for audio output.
Referring now to FIG. 7, the next time the client 1 connects to the Internet, the client 1 automatically sends a request to appropriate “White Pages” database servers for the name of the source of the last telephone call (step 701 ), assuming Caller ID information was received for that call. The request includes the telephone number provided by the Caller ID service. Such Web sites containing “White Pages” telephone directory information are well-known. The telephone directory Web site allows the accessing party to search based on a given telephone number or name. Accordingly, the client 1 automatically looks up the telephone number from the Caller ID information using the telephone directory Web site (step 702 ). If the telephone directory Web site locates the telephone number (step 703 ), then upon receiving the name, the client 1 stores the telephone number and the corresponding name in memory 23 for future use (step 704 ). Hence, each time in the future an incoming call is received from that telephone number, the name of the calling party is automatically retrieved from memory 23 and displayed to the user (FIG. 6, step 604 ).
The present invention also includes a selective forwarding feature by which the user of the client 1 is automatically notified via e-mail or telephone when an incoming telephone call is received from a specified source, even if the user is at a geographic location different from that of the client 1 . The user initially selects a message forwarding option and inputs an identity of a calling party to the client 1 . The identity may be specified in the form of a telephone number or a name. Number buttons on remote control 11 can be used to enter the digits of a telephone number. To enter alphabetical characters of a name, the user can select soft buttons within an image of a keyboard that is displayed on television set 12 . Alternatively, the characters can be entered through the use of a wireless keyboard. The user also selects a forwarding mode as either “e-mail,” “telephone,” or both and inputs a destination e-mail address and/or telephone number designating the location to which the forwarding message is to be sent.
FIG. 8 illustrates a routine by which the client 1 forward messages to the user at a remote location. When an incoming call is received, then if the user has selected the message forwarding option (step 801 ), the client 1 determines whether the calling party identity specified by the user matches the Caller ID information (step 802 ). If the user-specified identity was provided as a name, the client 1 uses the identification procedures described above to determine if there is a match. Specifically, the client 1 determines whether the telephone number in the Caller ID information is stored in memory 23 and, if so, whether there is a corresponding name stored.
If the Caller ID information does not match the user-specified caller identity, the standard routine for handling incoming calls is performed (step 805 ). If, however, there is a match, then the client 1 waits until the line is clear (i.e., no incoming call is being received and all handsets are on the hook) (step 803 ). When the line is clear, the client 1 automatically dispatches a message to the location specified by the user. The message may be a default message or a user-created message. If the telephone mode was selected, the client 1 will automatically dial the user-specified destination telephone number and play a pre-recorded message if the call is answered. Hence, using the above technique, the user is notified immediately when a specified party calls, even when the user is located away from the client 1 .
The present invention also provides conventional e-mail capabilities. E-mail addressed to a WebTV™ user is stored in the WebTV™ server 5 . When e-mail addressed to the user is received by the server 5 , the server 5 signals this fact to the client 1 if the client 1 is presently connected to the server 5 . Upon receiving this signal, the client 1 provides an indication to the user that the user has e-mail. The indication is provided in the form of a lighted LED (Light-Emitting Diode) built into the housing of WebTV™ box 10 , a text message displayed on television set 12 , or both. In one embodiment of the present invention, the client 1 automatically dials out and connects to the WebTV™ server 5 at regular intervals or at specified times of the day to determine whether the user has any new e-mail, and both downloads any e-mail into memory (e.g., RAM 23 ) for fast retrieval and illuminates the LED.
Another feature of the present invention relates to reducing costs associated with ISDN service. As mentioned above, the client 1 has both a standard telephone connection 29 a and an ISDN connection 29 b with the server 5 . It is well known that an ISDN connection permits faster data communication than a standard telephone connection according to the present state of the art. However, ISDN service tends to be more expensive than standard telephone service. Consequently, the present invention provides a means for reducing communications costs associated with accessing the Internet. Specifically, the client 1 keeps track of the time of day and routes communications through the ISDN connection 29 b during hours which are not considered “prime time” for ISDN usage. However, the client 1 automatically directs communications through the standard telephone connection 29 a during ISDN prime time, when rates are most expensive.
In another aspect of the present invention, the client 1 automatically disconnects from the WebTV™ server 5 when no input from the user is received for a predetermined period of time. The current browsing status is saved to memory 23 before disconnecting, as described above. The connection is automatically reestablished and the most recent browsing status is resumed as soon as the user enters any input which requires access to the network. Hence, the user is not required to initiate a specific log-in procedure in order to resume browsing.
Thus, a method is provided, in a client processing system coupled to a server processing system, of managing communications between the client and the server. Although the present invention has been described with reference to specific exemplary embodiments, it will be evident that various modifications and changes may be made to these embodiments without departing from the broader spirit and scope of the invention as set forth in the claims. Accordingly, the specification and drawings are to be regarded in an illustrative rather than a restrictive sense. | A client is coupled to a modem pool and a server by a communication link in a wide area network. The client allows a user to browse the World Wide Web in response to user inputs entered at the client device. The communication link to the client is shared by a telephone circuit at the client end of the link. A disruption in communication with the server may occur due to a Call Waiting signal caused by an incoming telephone call, or due to another user picking up a telephone extension associated with the client. In response to such a disruption, the client saves the browsing status after which communication with the server is terminated. When the telephone line is once again available for connecting to the server, the client uses the browsing information saved to reconnect to the Web page that was displayed by the client at the time of the disruption. | 7 |
This application is a Continuation-In-Part of the application bearing U.S. Ser. No. 07/268,178, filed in the Patent Office on Nov. 7, 1988, by the same inventors, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to ratcheting tools such as torque wrenches. More particularly, the present invention relates to an improved ratcheting tool having a reduced angle of latchability for use in a confined space
2. General Background
In several industries, particularly of the type utilizing structural components which require the tightening down nuts with a very large torque in the magnitude as high as 50,000 foot lbs. in order to create the proper feel in the line. There have consequently been developed a series of type of wrenches known as torque wrenches, which are for the most port hydraulically controlled wrenches, and utilize a type of ratcheting mechanism which is quite common so that the wrench can be hydraulically operated in order to achieve the required high torque, yet on the other hand attempt to operate as with a ratcheting wrench in a more confined area than one would normally be able to undertake.
One of the most recent types that have been developed is disclosed in U.S. Pat. No. 4,669,338, entitled "Ratcheting Box Wrench", wherein there is utilized a standard wrench body connected to a reciprocating power head. There is included a tool head assembly having an aperture which would be placed upon the work piece. The ratcheting mechanism of the wrench would include the ratchet gear having a series of arcuate channels equally spaced around the circumference of the gear, for providing a recess in which a series of roller drive pins are positioned in and out of in order to provide a ratcheting motion. When the roller drive pins are in the arcuate channels there in the drive position for rotating a flange nut. When the tool head assembly is ratcheted back to its original position, all of the drive pins slip into a ratcheting slot of the tool rim and are positioned and held in place for the drive portion of the cycle by one spring located on both sides of the roller drive pins so that the pins move into the ratcheting gear against the bias of the spring attached to the head assembly. Each of the drive pins are located 30° apart, and therefore when the pins are moving from one arcuate slot to the next in order to accomplish the ratcheting function, there is what is called a 30° latchability requirement in that the handle of the tool must move 30° in order to move into the next ratcheting motion. This 30° movement by the handle is a distance which is oftentimes prohibitive in that the handle is in a more confined area, and therefore 30° latchability is undesirable.
There are numerous other patents which have been issued on the subject of torque wrenches, these patents are being provided herewith in te accompanying statement of the art, accompanying this application.
This application is a Continuation-In-Part of an application bearing U.S. Ser. No. 07/268,178, filed Nov. 7, 1988, in the U.S. Patent Office by the same inventors, which provides an inline ratcheting tool having retainer grooves spaced apart at 45° in arcuate channels and a ratcheting gear spaced apart at 30°, with the 45° to 30° crossover allowing a 15° movement of the ratcheting head. That application is incorporated hereunto by reference.
SUMMARY OF THE PRESENT INVENTION
One embodiment of the apparatus of the present invention solves the problem in the art of ratcheting tools, in that there is provided an inline ratcheting tool having a latchability of 15°, and therefore solving the problem of working the tool in a confined area. There is provided a wrench body pivotally connected to an end of a reciprocating power source, a tool head assembly attached to the opposite end of the reciprocating power source, which would include a tool head, having an aperture for the work piece, a solid tracking tool head and for being matingly slidable into a surface of the wrench body; a retainer rim having at least two retainer grooves; at least two roller drive pins positioned within each of the retainer grooves, and each biased away from the retainer rim by a separate leaf spring inserted between the wall of the rim and each drive pin; a ratcheting gear operative attached to the tool body and positioned in the aperture for connecting the work piece, the ratcheting gear having a plurality of axially aligned and beveled channels along the perimeter of the gear so that one o the drive pins are received into at least one of the channels, in order to achieve the ratcheting function, and through a movement of 15°, the second ratcheting pin is positioned within a channel, for reestablishing the ratcheting motion, while the first pin resumes its position within the retainer groove.
In a second embodiment, the apparatus would comprise a channel for guiding the tracking arm, the channel formed by a plurality of rollers along the upper portion of the tracking head, and the outer arcuate wall of the ratcheting gear housing for reducing the friction encountered by the movement of the tracking arm. Furthermore, each of the drive pins are provided with a insert spring protector secured to the interior face of the grooves housing each of the drive pins, with the protector accommodating a pair of coiled springs for exerting force against the wall of each of the drive pins or urging the drive pins out of the groove in engagement with the ratcheting gear, and further providing a means to allow the springs to be coiled by the force of the drive pin being returned into the groove, but to be protected against being crushed by the drive pin within the slot.
It is therefore a principal object of the present invention to provide an inline ratcheting tool having 15° latchability during use;
It is a further object of the present invention to provide an inline ratcheting tool which provides for ratcheting in a confined space, the use of a single drive pin driving the tool between a ratcheting gear and the ratchet tool body; and
It is still a further object of the present invention to provide an inline ratcheting tool having retainer grooves spaced apart at 45° in arcuate channels in a ratcheting gear spaced apart at 30°, with the 45° to 30° cross over allowing a 15° movement of the ratcheting head;
It is still a further object of the present invention to provide an inline ratcheting tool wherein one embodiment provides a plurality of roller members to define the upper wall of an arcuate channel in which the tracking arm moves with reduced friction during the ratcheting process;
It is still a further object of the present invention to provide an inline ratcheting tool which allows spring biased drive pins to be forced into the respective drive slots without crushing the spring that would urge them out of the slot during the operation of the ratcheting gear.
BRIEF DESCRIPTION OF THE DRAWINGS
For a further understanding of the nature and objects of the present invention, reference should be had to the following detailed description taken in conjunction with the accompanying drawings, in which like parts are given like reference numerals, and wherein:
FIG. 1 is an overall view of the apparatus of the present invention;
FIG. 2 is a cross sectional view of the preferred embodiment of the apparatus of the present invention;
FIG. 3 is an exploded view of the preferred embodiment of the ratcheting portion of the preferred embodiment of the apparatus of the present invention;
FIG. 4 is a top view of the preferred embodiment of the present invention;
FIG. 5 is a side view of a pin member in the apparatus of the present invention;
FIGS. 6A and 6B illustrate in top and side view respectively the leaf spring members in the preferred embodiment of the apparatus of the present invention;
FIG. 7 illustrates a side view of an additional embodiment of the apparatus of the present invention;
FIG. 8 illustrates an isolated end view of the tracking head of the additional embodiment of the present invention;
FIG. 9 illustrates an exploded view of the additional embodiment of the apparatus of the present invention;
FIGS. 10A-10C illustrate isolated views of the drive pin mechanism in the additional embodiment of the apparatus of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The first embodiment of the apparatus of the present invention relates to an inline ratcheting tool 10, illustrated in FIG. 1. The inline ratcheting tool 10 is positioned on a head 11 of a nut 12. In operation, the body portion 13 of tool 10 would engage a second nut 12 to provide a base from which the inline ratcheting tool 10 will obtain the necessary leverage in order to operate. As illustrated in FIG. 1, there is further mounted on body portion 13 a hydraulic cylinder 15 having the hydraulic cylinder connectedly engaged at its rear end 15 to the upper body portion 16 of body 13, and the cylinder having a piston member 17 for engaging the ratcheting means 18 (as will be discussed further), so that as the piston moves forward and rearward from the flow of hydraulic fluid in lines 19 and 21, ratcheting means 18 operates to tighten or loosen nut 12.
As is further illustrated in FIG. 1, piston 17 is attached to a tracking head 22, which extends from a tracking rail 24 (FIG. 2) mounted along an arcuate tracking arm 26 attached to the ratcheting means 18.
Turning now to ratcheting means 18, there is provided a circular ratcheting gear housing 28, having a peripheral edge 30, encircling the housing 28, and integrally attached to the tracking arm 26. Gear housing 28 includes a circular enlarged bore 32 which defines an interior bore wall 34 of housing 28. There would be positioned within the bore 32 of housing 28 a circular ratcheting gear 36 of the type having a central cutout portion 38 for accommodating the work piece, such as a nut 12 or the head of a bolt, and the remainder of the gear 36 defining a peripheral surface 40 slidably accommodated within bore 32 of housing 28 along the interior surface 34 of housing 28. Peripheral surface 40 of ratcheting gear 36 contacts interior surface 34 of housing 28 along is circular wall, and would further comprise a plurality of arcuate ratchet channels 42 positioned equally distant apart along the outer peripheral wall 40 of gear 36, there being in the preferred embodiment a total of twelve peripheral ratchet channels 42, each being approximately 30° from center to center. There is further provided upper and lower rings 37 and 39 respectfully, (FIG. 3) attached to the outer walls of body 28, with screws 41 to maintain ratchet gear 36 in position within bore 32.
Ratcheting gear 36 would work in conjunction with body portion 28, in that body portion 28 would include at least two retainer grooves 44A and 44B cut into the body of housing 28, each of the grooves having a parallel sidewall 46, and a flat rear wall 48, for defining the groove space 45 there within. Each of the grooves would be at a depth to accommodate a drive pin 50A aand 50B respectfully, which would be a metallic pin extending within each groove 40A, 40B, and of the same width as the width of body portion 28 as seen in FIG. 3. The drive pins 50A and 50B, would be of a diameter slightly smaller than the width of box of the retainer grooves, so that the drive pins may move in and out of each groove rather easily during use of the ratcheting apparatus.
Turning now to the operation of the apparatus, each drive pin 50A, 50B is provided with a spring member 60, which is a type of leaf spring having a flat raised body portion 62 with a pair of flexible arm portions 64 extending from the body portion 62 and having a pair of feet 66, with spring 60 positioned between the rear wall 48 of groove 44 and each drive pin member 50A, 50B so that the drive pin member when fully set within each groove 44A, 44B would be set against the bias of the leaf spring 60, with the leaf spring 60 being in the flattened mode as seen in FIG. 2.
In operation, the manner in which each drive pin would lockingly engage between the ratchet gear 36 and the gear body 28 is illustrated by drive pin 50A (FIG. 1) wherein an arcuate ratchet channel 42 has aligned itself with box groove 44A, and therefore spring 60 would be allowed to flex and move the pin member 50A from its position within the groove 44A, to its position partially set within arcuate channel 42. Therefore the ratchet could move no further due to the fact that the body of pin member 50A is lockingly engaged between gear 36 in relation to the stationary position of body 28. Likewise, when pin 50B is engaged in its ratcheting position, pin 50B is totally confined within second channel 44B and leaf spring 60 has been biased to its flat position as seen in FIG. 1. Pin 50B is held in position within groove 44B by the outer wall 40 of ratchet gear 36, i.e., that portion of the wall 40 intermediate a pair of ratchet channels 42.
As was stated earlier, in the design of the relationship between the gear body 28 and ratchet gear 36, if one were to draw an imaginary vertical line 80 along with the center most point of gear 36, there is a 45° angle 82 between first rectangular retainer groove 44A and second rectangular retainer groove 44B. Further, arrow 83 illustrates the 30° angle relationship between each of the arcuate channels 42 formed in the ratcheting gear, the points of which will be discussed further. Likewise, in the position as seen of the pin members as seen in FIG. 1, when pin member 50A is in the ratcheting mode, the arcuate channel in which pin member 50A is set is approximately 15° from the vertical line 80 as indicated by arrow 84. Likewise, when pin member 50B is simultaneously totally confined within groove 44B the retainer groove 44A is 30° from the vertical line 80 as indicated by the arrow 86. Therefore, as ratchet groove 42 turns in the direction position of arrow 70, ratchet gear 36 will move a distance from the point as is illustrated in FIG. 1, to the position that it will be in directly beneath pin 50B so that pin 50B may slide into the arcuate channel 42 for ratcheting. Therefore that movement will be a movement of 15° and simultaneously pin member 50A will slide out of arcuate channel 42 and will be lockingly engaged within retainer groove 44A while drive pin 50B is in the ratcheting mode. Therefore, during operation each of the pins 50A, 50B alternate in ratcheting function, and as one moves into the ratcheting mode, and the other moves out of the ratcheting mode the ratchet gear has only moved a total of 15° as opposed to the prior art, which requires a movement of at least 30°. Therefore, there is a 100% reduction in the swing of the wrench during use which of course translates into a more efficient wrench which can be used in a much more confined area than there is presently known.
In effect, the drive pin is positioned in each of the retainer grooves with each of the drive pins independently spring biased toward moving into the ratcheting channel as the channel moves into alignment with the retainer groove. The retainer grooves are spaced apart so that only a single drive pin secured within a single retainer groove will effect the ratcheting mechanism and the second drive pin is maintained in the retainer groove. A 45° spaced retainer groove in the tracking head is in relation to a 30° ratcheting gear. Therefore, a 45° to 30° cross over of the two allows that a 15° movement of the head will cause the ratcheting pin to be secured within the ratchet channel. As was stated earlier, this 45° to 30° cross over allowing a 15° movement of the head to effect ratcheting allows the tool to be used in a very confined space, and therefore solves the problems that are confronted in the art.
Furthermore, the use of the "half moon" arcuate channels in the ratcheting gear provides that the forces placed on pin members 50A and 50B are in the direction more towards the center of the ratcheting gear and less as a tangential force along the outer surface of the gear, as found in the prior art which utilized the "tear drop" type channels along the wall of the ratcheting gear. In addition, the wear on the arcuate channel is reduced as opposed to the tear drop channel, and if wear is found, the gear may be reversed so that the force is applied to the other part of the channel.
FIGS. 1 through 6-B illustrated a first embodiment of the present invention by the numeral 10. In FIGS. 7-10B, there is illustrated an additional embodiment of the apparatus, designated by the numeral 110. For purposes of explanation, each embodiment 10 and 110 operate similarly to carry out the task of an in-line ratcheting tool, and therefore, any explanation concerning the general manner in which the tool operates, will be as was discussed in the first embodiment. Therefore, the explanation of the components of the additional embodiment will be identical to the first embodiment and can be clearly seen in FIGS. 1-6B. However, with the improvements in the system, as illustrated by the FIGS. 7-10B, the components which comprise these improvements will be discussed, and will be designated as such. If any part is not designated in the new embodiment, it is due to the fact that that part is discussed in the first embodiment and is present in the additional embodiment a well.
Initially, as seen in FIG. 7, there is provided the tracking head 22, which extends into an enlarged body portion 23, and eliminates the fixed tracking rail 24. In the first embodiment, the tracking arm moves within an arcuate channel 26 defined by the tracking rail 24 above and the ratcheting gear housing 18 below to define traveling channel 26. However, in this additional embodiment, as illustrated in FIG. 7, an arcuate tracking arm 126 is defined by a plurality of rollers 128, spaced apart in an arcuate fashion along the length of the body 23 of tracking head 22, for defining a continuous upper surface upon which the tracking member can engage while travelling along. As illustrated, particularly in FIG. 8, the rollers 128 are positioned on either face of the tracking rail 24, and are free rolling members, each pair of rollers 128 on each side of the rail 24 supported by a single axle member 129 extending through the rail 24, and supporting a roller 128 at each end.
The lower face of the arm 126, as with the principal embodiment, is defined by the upper wall 130 of the ratcheting gear housing 18 as illustrated. Therefore, as seen in FIG. 8, in end view, the upper plurality of rollers 128 and the lower ratcheting gear housing 28 to define the arcuate tracking arm 126 on the tracking rail 24 to accommodate the travelling of the body member therethrough during operation of the tool. The plurality of rollers 128 provide a means to reduce the friction between the movement of the body member traveling along the arcuate arm 126, and provides a great improvement in the overall operation of the wrench. Likewise, the rollers 128 are able to withstand the same amount of force as the tracking rail 24 in the first embodiment.
Reference is now made to FIGS. 10A through 10C which illustrate yet another important improvement over the first embodiment of the present invention. In the first embodiment, the drive pins 50 were housed in grooves 44A and 44B, and there was further provided a leaf spring 60 positioned at the base of each groove which served to urge each drive pin 50 into engagement with a ratchet channel 42, when the channel aligned with the respective drive pin 50. However, the leaf springs are limited, in that their ability to retain memory becomes reduced over time, so therefore the urging of the drive pins 50 into engagement is reduced.
In the additional embodiment as illustrated in FIGS. 10A-10C, the leaf spring has been replaced with a combination of elements to solve several problems encountered in the first embodiment. As illustrated, the leaf spring 60 has been replaced by a pair of coil springs 160, each pair positioned at the base of each of the grooves 44A and 44B, and making contact along the length of each drive pin 50, and, like the leaf spring, urging the drive pins 50 out of the channels for engagement with the ratchet channel 42 during operation.
However, it is known that when the drive pins 50 are forced to retract into the grooves, by the outer wall of the ratcheting gear 36, as seen in FIG. 7, the coil spring 160 may be required to coil or "crush" into a configuration that would reduce or perhaps eliminate its ability to recoil. Therefore, as illustrated, there is provided, secured to the base of each channel 44A, 44B, a retainer body 170, having a pair of bores 172 therethrough, each bore 172 of slightly greater diameter than the diameter of the spring 160, and accommodating each spring 160 therein. The thickness of each of the retainer bodies 170 is of a thickness so that, when springs 160 are extended (FIG. 10B), the outer end 162 of each spring 160 extends past the outer face 174 of each retainer body 170, and exerts force upon the drive pin 50, to position the pin 50 into driving engagement on the ratcheting gear 36, as seen in FIG. 10-B. However, when the pin 50 is required to retract into the groove 44 (FIG. 10C), the pin 50 can only retract the distance until it makes contact with the outer face 174 of the retainer body 170. This manner of preventing the pin 50 from retracting any further, allows the springs 160 to coil against the movement of the pin 50, but, only to a certain extent. Therefore, the springs 160 are coiled within the bores 172 of the bodies 170, but are protected from being crushed by the pins 50. This, naturally, greatly increases the life of the springs 160, and allows the pins 50 to move within the grooves 44A, 44B more uniformly to insure proper contact with the ratcheting gear 36 during operation of the tool.
It should be noted that to compensate for the thickness of each retainer body 170, each groove 44A, 44B would have to be channeled out slightly deeper than with the first embodiment so that the drive pins 50 can be fully accommodated within the grooves.
Because many varying and different embodiments may be made within the scope of the inventive concept herein taught, and because many modifications may be made in the embodiments herein detailed in accordance with the descriptive requirement of the law, it is to be understood that the details herein are to be interpreted as illustrative and not in a limiting sense. | A wrench body pivotally connected to an end of a reciprocating power source, a tool head assembly attached to the opposite end of the reciprocating power source, which would include a tool head, having an aperture for the work piece, tracking arm attached to the tool head and for being matingly slideable into a surface of the wrench body; a retainer ring having at least two retainer grooves; at least two roller drive pins positioned within each of the retainer grooves, and biased away from the retainer rim by a leaf spring inserted between the wall of the rim and each drive pin; a ratcheting gear operative attached to the tool body and positioned in the aperture for connecting the work piece, the ratcheting gear having a plurality of axially aligned and beveled channels along the perimeter of the gear so that one of the drive pins are received into at least one of the channels, in order to achieve the ratcheting function, and through a movement of 15°, the second ratcheting pin is positioned within a channel, for reestablishing the ratcheting motion, while the first pin resumes its position within the retainer groove. A second embodiment would provide a plurality of rollers to particularly define the tracking arm, and a pair of springs to work with the drive pins. | 1 |
RELATED APPLICATIONS
[0001] This application is a continuation of application Ser. No. 13/723,044, filed Dec. 20, 2012, which '044 application is a continuation of application Ser. No. 11/890,270, filed Aug. 4, 2007, now abandoned, which '270 application is a continuation of application Ser. No. 10/857,834, filed Jun. 2, 2004, now U.S. Pat. No. 7,252,727 dated Aug. 7, 2007 and claims priority under 35 U.S.C. 120 from these applications. These applications are incorporated by reference herein.
FIELD OF THE INVENTION
[0002] The present invention relates to prevention of water damage to balsa wood cores of fiberglass boat hulls.
BACKGROUND OF THE INVENTION
[0003] Fiberglass boats are typically constructed using an inner and outer fiberglass skin separated by a balsa wood core. The balsa wood core is in the form of small separate blocks preattached to a fabric or fabric like material mesh on one side only. This allows the separate blocks to tilt in two directions relative to each other to readily follow the convex contours of a boat. The spaces between the separate blocks are called veins.
[0004] While the balsa wood is very light weight and offers adequate crush resistance (on end grain), it is quite vulnerable to water infiltration between the fiberglass skins of a boat which in time may cause the core to decay and then eventually to rot. Typically when this happens, the boat owner puts off repair until the damage is extensive or structural integrity is compromised since the current method of repair is drastic. This expensive procedure involves de-skinning of entire outer fiberglass covering, replacement of the damaged balsa core, and then replacement of the outer skin. This entails hundreds of person-hours of effort and can take a boat out of service for an entire season.
[0005] Examination of the prior art reveals several patents related to localized repair of non-metallic structures or objects. U.S. Pat. No. 2,307,958 of Hellier relates to a method of repairing rubber vehicle tires by using air pressure to locate and dry ply separations, by injecting the dry air through a hole with a hollow needle. A cement is then injected to reattach the separated plies.
[0006] U.S. Pat. No. 4,236,951 of Krchma et al. relates to a method of treating blisters in asphaltic membrane covered roofs. A selected liquid hydrocarbon miscible with the asphalt of the membrane is introduced through a flexible hose with a puncture output nozzle, and the liquid hydrocarbon is used to heal the localized blistering of the asphalt.
[0007] U.S. Pat. No. 4,260,439 of Speer is related to an apparatus and method of plastic repair such as of vinyl seat covers. It involves the use of a tool with a narrow jet of heated air to cure a heat curable repair compound.
[0008] Clearly these patents do not teach techniques which can be applied to the repair of fiberglass boat hulls. However, U.S. Pat. No. 5,622,661 of Cederstrom is a method of localized repair of surface blisters of laminated plastic objects including fiberglass boat hulls. Cederstrom '661 is primarily involved with osmosis type damage to the exterior boat hull skin.
[0009] Using a combination of controlled heat or cooling with mechanical action of a strong compressed air jet, in Cederstrom '661 the damaged area is cleaned and dried in a single operation using a HYAB-osmosis tool. Damaged material below the skin is not removed; instead it is reinforced with a penetrating epoxy.
[0010] A similar system is noted in the website of Star Distributing Corporation of Mystic CT in their excerpt entitled “Cost Effective Restoration of Decay in Wooden Core Fiberglass Boats©”. Star Distributing describes a time-consuming method for repairing wood damaged boat hulls by tapping the boat with a mallet to estimate wood damaged areas by listening for hollow echo sounds, drilling holes in those estimated areas, letting the wood damaged areas dry by ambient air and heat, and then pouring Clear Penetrating Epoxy Sealer (CPES) into the estimated damaged portions of a hull. The method of Star Distributing does not physically remove damaged core; it just treats it with poured CPES. The method of Star Distributing dries out areas with rudimentary ventilation and heat, but not with a system of vacuum plates and sources to facilitate controlled drying and removal of moisture. The only mention of vacuuming in Star Distributing is to a usual domestic vacuum cleaner, but Star Distributing uses a vacuum to remove drill waste, airborne fiberglass particles and water leaking from the lowest drilled hole.
[0011] In addition, the method of Star Distributing does not physically remove damaged wood core areas; it only treats drill-exposed areas with poured-in CMES, leaving unexposed, damaged wood core areas which may not be in contact with the CPES, and which may cause further wood rot damage in the future.
[0012] Initially, tapping the surface is used by both Star Distributing and optionally by the present invention. But the present invention goes much further. After initial tapping, then the present invention uses the moisture meter/infrared camera, which can accurately predict not just hollow areas, but non-hollow, moisture-ridden areas. The present invention uses an analytical grid pattern, dries wood-infested areas with heat and vacuum, then re-tests the dried areas with the moisture meter/infrared camera, after using the vacuum plate sub-system.
[0013] Star Distributing does not remove damaged areas; it only treats them with CMES. In contrast, the present invention uses augers and bits to remove out rotted core; Star Distributing only dries it.
[0014] The present invention uses moisture meters to locate water. The present invention uses grids to make moisture location more accurately, and to take notes for future moisture testing. But Star Distributing just pokes holes to examine wood thereat.
[0015] If there is water present, Star Distributing uses a vacuum cleaner to remove water at lowest point. The present invention uses vacuum to pull in air from upper holes and leaves it on for days, to facilitate drying. The present invention's continuous vacuuming facilitates fast drying of the core. Star Distributing dries by allowing approximately 1 week drying. But the present invention uses multiple measuring and monitoring with moisture meters and similar devices to ascertain proper drying.
[0016] Both Star Distributing's and the present invention's techniques are minimally invasive. But the present invention removes rotted sections of wood core and dries out non-rotted wet areas. Unlike Star Distributing, the present invention uses flexible cable tools and bits to remove rotted wood. The present invention preferably uses chopped fiberglass and epoxy to replace wood core. Star Distributing physically fills bare areas where the present invention removes rotted wood. But Star Distributing, after drying the wood core (whether bad or good) doesn't teach removing wood rot. Additionally, Star Distributing relies heavily by using the mallet tapping to locate holes representing separation of wood from fiberglass (de-lamination). Such a reliance does not rise to the level of sophistication of the present invention, which can detect moisture infested areas even if there is no separation of the fiberglass skin from the adjacent water infested wood core areas.
[0017] After drying by ambient air over time (one week), Star Distributing uses liquid CPES that is soaked up by wood that takes a long time to dry. After ambient drying, Star Distributing adds another CPES in-filling. The CPES coat is poured in to replace wood lignum lost to bacterial consumption. In contrast, the present invention is removing and replacing the damaged wood.
[0018] Unlike Star Distributing, the present invention also has optional preventive maintenance Star Distributing does not remove damaged wood, but fills drilled plug holes with Fill It and Layup and Laminating Epoxy (LLE). Star Distributing's main emphasis is use of poring in CPES to the damaged wood.
[0019] Clearly, the repair methods of Cederstrom '661 and Star Distributing are different from the present invention. Cederstrom '661 and Star Distributing do not extend the method to a systematic analysis of a fiberglass boat hull having a balsa wood core, by using moisture meter techniques to locate damaged areas not visible to the tapping or to the naked eye, and to heat and remove the damaged wood core with accurately measured minimal incisions of the fiberglass boat outer skin.
[0020] The invention of U.S. Pat. No. 5,277,143 of Franguela, Ship Hull Repair Apparatus, describes a device that can be rapidly deployed to repair a breach in the hull of a boat. It acts to plug the hole in the hull and is designed to be installed by a diver from the exterior in an emergency to stem the flow of water into the boat if the breach is below the water line. This apparatus will seal a hole in the hull of any type of construction (eg.—metal, fiberglass, wood) as long as it is sized to be compatible with the damage.
[0021] FIG. 1 of Franguela '143 shows the method of installation by a diver. FIG. 1A of Franguela '143 shows a perspective view of the apparatus showing the mounting plate (sealing disk) 15 with two pneumatic storage cylinders 39 and 40 which contain compressed air or other gas to operate the apparatus. The crossectional side view of FIG. 4 permits one to quickly grasp the operational features of the apparatus. In this view, the configuration is as stored and prior to installation. It will be appreciated that four legs (see FIG. 2) 20 through 23 would be pushed through the hull breach protruding into the inside of the boat hull. Pneumatic piston 34 within cylinder 16 is poised to pull on cables 37 which will pivot legs 20 through 23 into the configuration shown in FIG. 7 upon pressure released from pneumatic storage cylinder 44. This action locks the apparatus to the side of the hull aided by distal hooks such as 27 and 28. At this time, compressed gas is released from cylinder 39 to inflate annular sealing bladder 38 to form a water tight seal against the boat hull.
[0022] Although the repair is complete, there will be some hydrodynamic drag from the apparatus extending somewhat from the hull surface if below the water line. If above the water line or close to it, the repair also imposed aesthetic problems. Also, the repair may lose viability after long term use due to possible permeation of compressed gas through the flexible sealing bladder. For these reasons, the invention of Franguela '143 is considered to be an emergency and temporary repair apparatus.
[0023] In contrast to Franguela '143, the present invention is a repair system and method for fiberglass boats. The present invention is a system for locating core damage in fiberglass boat hulls while in dry dock, removing damaged wood core and repairing water intrusion damage to the damaged wood core areas. Further, drying apparatus involving the use of vacuum pumps and heaters are used to prepare the damaged areas for permanent repair. The method of the present invention is not designed to repair a hull breach which transverses both the outer and inner skins of a fiberglass boat, nor is the repair method applicable to wood or metal hull construction. Both the method and apparatus of the present invention bear no relation to the repair apparatus of Franguela '143.
OBJECTS OF THE INVENTION
[0024] It is therefore an object of the present invention to provide a system and method for repair of water damaged balsa wood cores within fiberglass boat hulls.
[0025] It is also an object of the present invention to provide for such a system, which minimizes surgical incision, and wholesale removal of large sections of the outer fiberglass skin of a boat hull.
[0026] Other objects will become apparent from the following description of the present invention.
SUMMARY OF THE INVENTION
[0027] In keeping with these objects and others, which may become apparent the system and method of the present invention replaces only those sections of rotted balsa core of a boat hull as needed while minimizing the damage to the outer fiberglass skin. In early stages of moisture attack, only sporadic regions and spots on the boat are damaged. The boat hull repair method of the present invention locates the damaged areas, dries out the damaged areas, repairs the damaged core, and prevents further damage by closing any leaks in the boat hull skins.
[0028] Early attention to these areas using methods of this invention greatly limits the labor content of the repair. Then, as part of the repair, analysis of the moisture entry paths and their repair would prevent further deterioration. The rotted balsa is removed by using rotary cutting tools, and alternatively the chips can be vacuumed out. A preferred embodiment entails the chips, foreign matter, or sediment to be blown out of the boat hull with a tool such as an air chuck or the like. The access to the bad areas is through relatively small holes in the outer fiberglass skin. The cavities thus formed are not refilled by balsa; instead a filled epoxy is used.
[0029] Suspected rotted areas are initially spotted by visual inspection, sounding, and “tug” tests. At this point, a moisture meter is used to verify the presence of water-saturated or moist wood; this is done through the outer skin. It is not a highly invasive procedure.
[0030] Once a region is identified as having water infiltration, a grid pattern is drawn on the outer fiberglass. A few core samples are taken with a hole saw. Rectangular openings below areas of wet core or wood are cut in the outer skin. Gasketed vacuum plates are attached to the side over these openings and a vacuum pump is attached using a manifold. Now a systematic moisture map of each grid location is made whereby the moisture content of the core is recorded along with the date. More core samples are taken where indicated by moisture readings.
[0031] As time goes on, moisture readings will decrease as the vacuum draws in heated dry air. Dry heated air under pressure can also be forced in above the wet core or wood regions. When the moisture reading is very dry (about 5%) the repair of the rotted areas can start.
[0032] Using commonly available tools and equipment, the wet core or wood areas of balsa are removed through small openings in the fiberglass shell. Both pneumatic and electrically driven hand tools can be used. Typically, straight and right-angle grinder drivers are used with butterfly cutters, de-burring bits, and other types of de-veining tool bits. Using a drive motor with a tool at the end of a flexible shaft enables one to reach wet core or wood areas far from the edge of a core hole. Thus deep cavities can be made with minimal exterior damage. Wood chips and debris are usually removed by using a tool such as an air chuck or a powerful vacuum at the end of a hose attached to a commercial vacuum cleaner, alternatively any tool which can accomplish the same purpose commonly known to persons skilled in the art may be utilized.
[0033] However, the vacuum system attached to the vacuum plates is only used for the drying process. Large attached sections of damaged core are physically removed using a routing procedure with rotary tools and bits. Debris and smaller particles are vacuumed out using a vacuum cleaner.
[0034] Once the cavities are made, and after drying, epoxy is mixed with chopped glass mill fiber and the mixture is applied to fill the cavities using a manual or pneumatically driven caulking gun. The skin repair is made by sanding the repair flush with the outer boat contour, applying a seal coat, a gel coat and finally a barrier water proofing.
[0035] Instead of taking three months to cut open large sections of a boat hull, the selective incisions and treatment of a core damaged boat hull can be done in less than three weeks duration, with significant labor and material savings.
[0036] Therefore, the present invention provides a method for boat repair, which includes detecting troubled areas of the boat, such as water infested wood core areas. The repair procedure further includes boring relatively small cavities within the boat in relation to the troubled areas. Heat is applied to the troubled areas and water damaged particles are blown out and/or vacuumed from the boat through the holes.
[0037] Detecting troubled areas is accomplished by utilizing a moisture meter or a heat sensing thermal or infra-red camera to detect the presence of moisture damaged wood core between the inner and outer skins of the boat, or beneath the deck or roof areas of the boat.
[0038] Once the moisture-ridden areas are located, areas of the boat are in a grid marked to clearly identify the troubled areas. Typical markings associated with the grid include recording the date and amount of moisture in each grid square if deemed necessary.
[0039] Additionally, the method for boat hull repair includes a search in finding the trough of the boat where water accumulates.
[0040] Once the areas are identified, the holes are drilled, at suspected damaged areas, and an auger removes particles from within the boat.
[0041] While straight augers can be used near the drilled holes for relatively inaccessible areas away from the drilled hole, a flexible auger removes particles from within the boat.
[0042] An auger can also be utilized to aid in facilitating the airflow within the boat.
[0043] As part of the repair process, heat is applied with a heater, such as a gas driven heater, an electric heater, an infrared heater, a convection heater or by placing the boat within a temperature control room. The heat dries out the moisture, allowing the water damaged particles to be removed and replaced. Heat may be selectively applied to damaged areas, or to the entire boat.
METHOD OF OPERATION
[0044] The methods of this invention are intended to identify and repair all wet core hull areas and to perform preventive maintenance on dry hull areas to restore the integrity of a fiberglass boat hull and to prevent new water infiltration damage beyond the level of a new hull.
[0045] The wet area repair guidelines using a surface moisture meter such as a model GRP33 use the following criteria. Any balsa cored area reading 15% or above is considered a wet area. Any wood cored area reading 20% or above is considered a wet area. In addition, any balsa/wood cored area with a relative difference of 5% or more than the average moisture reading of the surrounding area is considered wet and must be repaired.
[0046] An overview of the repair steps involves removing all through-hull fittings or hardware. Wet core areas are then dried out using heat lamps, lights or heaters, hot-vac systems, or octopus vacuum with grid system. If necessary, any area not drying out is de-cored and repaired accordingly. After repairs are finished, all through-hull fillings or hardware is reinstalled using new sealant. The recommended sealants are 3m 4200 Marine Grade Sealant/Adhesive for both below the waterline and above the waterline.
[0047] The preferred methods of repair are well described in the above sections of the invention relating to a minimally invasive procedure requiring the drying out of wet core areas. These methods offer great benefits in reduced labor costs; they are described in the text above and FIGS. 1 through 9A . In cases where the core is not responding to drying attempts, the areas are de-cored. This can be accomplished either from the interior, as detailed in the discussion of FIG. 11 , or from the exterior in a similar procedure. If performed from the interior, clear access must be provided to the repair area. All equipment, sole plates, insulation, and all other items that may prevent clear access must be removed prior to the repair.
[0048] Obviously, all removed items must be replaced after the repair. If the de-coring is performed from the exterior of the hull, access is more easy. The procedure is similar to that in FIG. 11 , but it is the outer laminate instead of the inner laminate that is penetrated. Also, It is the schedule and finish of the outer laminate that must be matched in the final steps.
[0049] The general preventive maintenance guidelines call for three different approaches applicable to three different regions of a hull. First, all dry areas below the waterline are to be disassembled, de-cored and reassembled with new sealant. The steps in this procedure are detailed in the discussion of FIG. 12 . Secondly, all dry areas above the waterline will be cleaned of all old sealant around the outside edge of the hardware; then the hardware is resealed from the exterior with a new bead of sealant. Third, all gunnel/stainless is removed and inspected. The steps for preventive maintenance of this region are described in the text for the maintenance chart of FIG. 10B .
BRIEF DESCRIPTION OF THE DRAWINGS
[0050] The present invention can best be understood in connection with the accompanying drawings. It is noted that the invention is not limited to the precise embodiments shown in drawings, in which:
[0051] FIG. 1 is a perspective view of a prior art boat hull repair method, wherein a portion of boat hull with a major part of the fiberglass skin is peeled away, revealing the damaged areas of the core;
[0052] FIG. 1A is a perspective view of a moisture meter used in diagnosing a moisture damaged core of a fiberglass boat hull requiring treatment according to the system and method of the present invention;
[0053] FIG. 1B is a perspective view of a collection of fabric backed balsa wood core blocks inside a boat hull, shown with the outer fiberglass skin layer removed;
[0054] FIG. 2 is a front elevational view of a portion of a boat hull being treated in accordance with the system and method of the present invention;
[0055] FIGS. 2A and 2B are side elevational views of grid systems shown depicted upon respective left and right sides of a boat hull, showing sources of water intrusion, such as port hole windows and motor vent holes;
[0056] FIG. 3 is a close-up perspective detail view of a vacuum draw plate used in connection with vacuum cleaning of moisture and damaged wood core debris of a boat hull being treated in accordance with the system and method of the present invention;
[0057] FIG. 4 is a close-up perspective view of the vacuum system of the present invention;
[0058] FIG. 4A is a perspective view of the vacuum and pressure systems shown in place at a boat hull to be repaired;
[0059] FIG. 5 is a close-up detail view of saw equipment used for introducing incision holes of the system and method of the present invention;
[0060] FIG. 6 is a perspective view of a straight oriented hand-held drilling and routing tool of the system and method of the present invention;
[0061] FIG. 7 is a is a perspective view of a bent, right angle oriented hand-held drilling and routing tool of the system and method of the present invention;
[0062] FIG. 8 is a is a perspective view of a flexible oriented hand-held drilling and routing tool of the system and method of the present invention;
[0063] FIG. 9 is a close-up elevational view of a portion of a boat hull being treated in accordance with the system and method of the present invention;
[0064] FIG. 9A is a close-up elevational view of a flexible auger used on a portion of a boat hull being treated with the system and method of the present invention;
[0065] FIG. 10A is a chart showing the relation between the different repair techniques of this invention for repair of wet core damaged areas in fiberglass boat hulls;
[0066] FIG. 10B is a chart showing the preventive maintenance techniques of this invention for different areas of a fiberglass boat hull. FIGS. 10A and 10B together constitute a combined chart entitled, “Repair and Maintenance for Fiberglass Hulls”;
[0067] FIG. 11 is a cutaway side view, taken as shown in the dashed line ellipse “11” shown in FIG. 9 , showing a damaged area of the hull with a wet core section, further showing the outer skin removed and showing various layers progressively downward and inward through the hull with a section of the inner laminate (skin) removed and the wet core area cut out with a bevel to effect a de-core procedure from the interior of the boat; and,
[0068] FIG. 12 is a close-up exploded view 12 of a hull detail with through-hull hardware shown as being just removed for preventive maintenance below the waterline taken as shown in the dashed line ellipse designated as “12” in the region of the porthole shown at the front end of boat hull 2 shown in FIG. 9 .
DETAILED DESCRIPTION OF THE DRAWINGS
[0069] FIG. 1 illustrates a prior art method of boat repair which involves peeling back of the fiberglass skin to locate and repair the damaged areas. Boat hull 1 is shown with part of the fiberglass skin peeled back 3 from its normal attached position 2 to reveal damaged areas 5 in the exposed balsa block core 4 . This analogous to “major surgery” as compared with the “laparascopic surgery” approach of this invention.
[0070] FIG. 1A shows an analog moisture meter 8 . Digital meters as well as moisture probes attached to PDA's or laptop computers are also available. Infrared cameras, or other remote moisture detectors, may also be used for thermal imaging of moisture presence.
[0071] FIG. 1B is a hull detail showing compound curve contour 20 , balsa blocks 23 , mesh 22 to which blocks 23 are preattached, and the inner fiberglass to which mesh 22 is loosely attached. Note that blocks 23 can adjust to hull contour 20 ; in so doing spaces or veins 24 are formed between the balsa blocks. These veins 24 often act as conduits for infiltrated water which is then conducted to damage larger regions.
[0072] FIG. 2 is an exterior hull section 1 with skin intact. Grid region 10 is drawn on the surface for a systematic moisture survey of the surface to locate damaged areas. Vacuum plates 14 are attached over openings in the hull to extract moisture from damaged areas via vacuum hoses 11 . Tape 12 is used to attach plates 14 to the hull.
[0073] FIGS. 2A and 2B show two different sides of boat 1 hull respectively. They show the location of port hole windows 6 and motor vents 7 .
[0074] FIG. 3 is a close-up of vacuum plate 14 . It preferably includes a preferably transparent plate 30 such as of polycarbonate, gasket 31 , such as of a flexible sealing material such as closed cell foam, which forms an airtight seal against the hull, and hose barb 32 for attachment to vacuum hose.
[0075] FIG. 4 shows a stand-alone vacuum system 35 . Commercial vacuum pump 36 is attached via large vacuum hose 37 to vacuum manifold 38 . Vacuum gauge 39 indicates vacuum. A number of hose barbs 42 are used for attachment of vacuum hoses 11 . Those barbs 42 not used are capped by seal caps 41 to prevent vacuum leakage.
[0076] FIG. 4A shows a combined vacuum and pressure center 45 . Vacuum pump 36 is powered by motor 46 which is plugged into outlet 53 . Intake line 48 from manifold to vacuum pump attaches to vacuum manifold 38 ; drain spigot 47 is to drain out accumulated water from the air drawn in by vacuum pump 36 . Vacuum hoses 11 are attached to vacuum plates 14 . The pressure supply side obtains compressed air from an external source via compressed air line 56 which is attached to air inlet filter 49 on air tank 50 . Electric heater 54 attached to outlet 53 heats the compressed air in tank 50 before it is distributed via compressed air manifold 55 and hoses 51 to line filters 52 . These lead to input openings in the fiberglass hull skin to aid in drying damaged areas. Compressed air gauge 40 indicates pressure at manifold 55 .
[0077] FIG. 5 shows hole saw equipment including electric drill driver 60 , mandrel 61 , and two sizes of hole saw 62 . A cordless version can be used as well.
[0078] FIG. 6 shows a straight pneumatic tool 66 powered by compressed air hose 68 with control valve 67 and veining bit 69 .
[0079] FIG. 7 shows right angle pneumatic driver 72 with control valve 73 , chuck 74 and butterfly bit 75 .
[0080] A flexible shaft driver 78 with flexible shaft 79 , guidepiece 82 , collet 81 and deburring tool 80 is shown in FIG. 8 . It can be electrically or pneumatically driven.
[0081] A section of attached fiberglass skin 2 is shown in FIG. 9 . It has core access hole 85 which enabled the removal of damaged core region 86 .
[0082] FIG. 9A illustrates the use of a modified flexible shaft auger 90 in removing damaged core creating cavity 98 through access hole 85 . Here adjustable stand 94 with hook 93 supports motor 91 via hanger loop 92 . Flexible shaft 95 feeds through a bendable semi-rigid outer covering 96 (like that of a gooseneck lamp) to emerge at guidepiece 82 . Collet 81 retains cutting tool bit 80 . The modification is the addition of sleeve 96 which permits tool 80 to be oriented in any direction to gouge out cavity 98 .
[0083] The repair and maintenance charts of FIGS. 10A and 10B illustrate the relationships between the different techniques of this invention in renewing the integrity of fiberglass boat hulls. In the repair chart of FIG. 10A , the first step is to locate the wet core areas as discussed above with the use of a moisture meter and possibly drawing a grid system on the exterior hull surface for accurate data collection of moisture content over time. While the preferred method of repair is the minimally invasive method discussed above (shown as the leftmost branch), in some cases, stubborn wet areas are found which do not respond to the drying techniques already discussed in detail. In these cases, either the inner or outer laminates or skins are actually removed over the entire wet area. This can be done from the interior whereby no repair is required on the highly visible exterior surface. In some cases, the wet area cannot be reached from the interior and the repair must be made from the exterior surface. This method of repair is called de-coring whereby the wet core section is actually cut out. Then, new core material is added, and the repair area is finished to blend in with the rest of the inner or outer laminate in the vicinity. This process is commonly done when the core is rotted. Alternatively, the outer skin is surgically cut in the vicinity of the water damage to facilitate drying of the cores which have no rot.
[0084] The dry areas of the hull are treated to three basically different preventive maintenance techniques as described by chart 10 B. Above the waterline, old sealant is cleaned or removed from around any hardware. Then a bead of new sealant is used to seal the exterior of the hardware.
[0085] All gunnel/stainless is removed and inspected. All broken or bent screws are removed, and misdrilled holes or deck-to-hull seams are repaired and/or sealed with sealant. The gunnel/stainless is then reinstalled with a new bead of sealant. Finally, drain holes are drilled in the gunnel molding on the underpart.
[0086] Below the waterline, all through-hull hardware is removed. Core material is carefully removed to a predetermined depth such as, between one to two inches from the edge of the cutout. The de-cored areas are then filled with epoxy before the hardware is reinstalled with new sealant.
[0087] FIG. 11 is a side cutaway view, taken as shown in the dashed line ellipse “11” shown in FIG. 9 , of an example of a wet area repair from the interior of the hull, illustrating the progressive steps encountered in the repair. In the cutaway view of FIG. 11 , the uppermost item shown is the vacuum suction cup 138 , which is placed above and having a connection through plastic bag 137 , under which is bleeder fabric layer 136 , then strip ply/peel layer 134 and the lowest layer, which is fiberglass level 121 . FIG. 11 also shows the affected region after inner laminate 122 is ground back until all damaged areas are removed Inner laminate 122 is tapered back at region 128 to a suitable taper, such as, for example, a 20:1 taper ratio and the wet core is removed with a tool, such as a sharp bevel. This area is further prepared by grinding or filling any voids with a filler, such as, for example, polyester putty. All dust and loose debris is blown out and/or vacuumed out of the area to be laminated. The next step is to apply the first layer of fiberglass. This involves solvent-wiping the prepared laminate area and then applying, for example, 2 oz/sq.ft. chopped strand mat (CSM) or other suitable material, to the repair area with a appropriate overlap, such as a two inch overlap, at the perimeter. This new laminate layer is then allowed to cure. The opposite skin and laminated perimeter 130 is prepared for replacement of the core by grinding to a near white condition and insuring the overlaps are smooth. The next step is to prep the new core. The new core is pattern cut and pre-fit to the repair area. The edges are machined to closely fit the beveled perimeter. All dust and foreign debris is again blown out and/or vacuumed out from the repair area. The next step is bedding of the new core material. Bagging of the core involves first placing a seal, such as tacky tape, around the perimeter of the prep area. The bedded surface of the balsa core is then primed with a primer, such as, for example, catalyzed V/E resin, before bedding. Next, using the V/E resin, chopped strand mat material, such as at least 2 oz/sq.ft. of the chopped strand mat (CSM) materials, are applied and catalyzed. Vacuum bag 137 is carefully sealed around the periphery using a seal, such as for example, tacky tape 132 . Vacuum is then applied through vacuum port suction cup 138 . After cure, bag 137 is removed. The core is ground and detailed, cleaned, and then primed with catalyzed resin. When resin is cured, any voids are filled with a filler, such as for example, polyester putty. All excess putty or resin/fiberglass are cleaned from the core. Repair area is then prepared for the replacement laminate by grinding the perimeter to a near white condition. The core is feather ground to eliminate any excess portion of excess putty. The area to be laminated is again vacuumed and cleaned. The final step is the step of installing the new surface laminate. The repair area to be laminated is solvent wiped, and then the original inside laminate schedule is applied. This involves installing the first laminate ply to overlap the existing laminate by an appropriate dimension, such as, for example, a minimum of two inches. Each successive ply should overlap the previous by a minimum dimension, such as, for example, of one inch. After curing, a light grinding of between each set of laminates is performed. Finally the exposed surface finish should replicate the original interior surface and be equal in finish to the existing production standard.
[0088] FIG. 12 illustrates dry area preventive maintenance procedures used below the waterline. FIG. 12 is a close-up exploded detail view of the region surrounding any through-hull hardware feature, taken as shown in the dashed line ellipse designated as “12” in the region of the porthole shown at the front end of boat hull 2 shown in FIG. 9 . In FIG. 12 , removed hardware 150 is shown removed from the porthole. Outer fiberglass laminate 121 , dry undamaged core 123 and inner laminate 122 are shown. The next step of the procedure includes the step where one appropriate sections 151 , such as for example, one inch deep sections, of core 123 are removed from between laminates 121 and 122 . After the cutout is cleaned out, de-cored regions 151 are filled with an epoxy 155 , such as, for example, West Systems Marine Epoxy. After epoxy 155 is set, it is sanded smooth. Then the true-hull hardware 150 is reinstalled with new sealant, such as for example, as 3M 5200 Marine Grade Sealant/Adhesive.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0089] The present invention has broad applications to many technical fields for a variety of articles. For illustrative purposes only, a preferred mode for carrying out the invention is described herein, wherein a repair system for treating boat hulls with rotted balsa wood cores utilizes a minimally invasive incision and treatment technique of the fiberglass boat hull.
[0090] As shown in FIG. 1 , in a prior art boat hull repair method, a major portion of boat hull 1 with a large part of the fiberglass skin 3 is peeled away from fiberglass skin 2 , revealing the damaged areas 5 of the balsa wood core of hull portion 4 to be treated and removed.
[0091] In contrast, in the present invention, general areas 5 of moisture damage to a boat hull 1 are determined by exposing the exterior surface of a boat hull 1 to a moisture detector 8 , such as a moisture meter as shown in FIG. 1A , or by other moisture sensing equipment, such as a thermal or infra-red camera. A typical moisture meter 8 has either a digital or analog output, showing moisture readings of from zero to about thirty percent moisture content on a relative scale extending from a very dry condition to a most condition and finally to a wet condition.
[0092] FIG. 1B shows a collection of fabric backed balsa wood core blocks 23 inside a boat hull 1 , shown with the outer fiberglass skin layer removed. The balsa wood blocks are shown slightly fanning outward along a rear curved inner fiberglass reinforced fabric mesh backing 22 attached to an inner fiberglass skin 21 , following a curve contour 20 of the boat hull 1 . The triangular area gaps located between adjacent balsa wood blocks 23 are defined as veins 24 , through which water intrusions flow, thereby damaging adjacent balsa wood blocks 23 . When water intrudes into the area between the inner fiberglass layer 21 and outer fiberglass boat hull skin layer 3 , these balsa wood blocks 23 are susceptible to moisture damage and rot, thereby interfering with the structural integrity of the inner buoyant core of the boat hull 1 .
[0093] As shown in FIGS. 2 and 9 , the boat hull repair system and method of the present invention removes the aforementioned moisture and water damaged wood core from within the fiberglass skin layers 3 and 21 of a boat hull 1 .
[0094] FIGS. 1 and 2 show a front view of a side of a boat hull 1 , typically comprising an exterior fiberglass skin 3 and an interior fiberglass skin layer 21 shown in FIG. 1B , both separated by a core of a plurality of small, flat edged balsa wood core blocks 23 connected by a flexible fiberglass reinforced textile mesh strips 22 , as shown in FIG. 1B , which allows the incremental placement of the individual, generally linear based, blocks 23 over one or more complex curves 20 of the boat hull. Typically the blocks 23 are one to two inches in length, with thickness' varying in a range of from about one quarter (¼) inch in thickness to about three quarters (¾) inch in thickness. Often the balsa wood blocks 23 are either three eighth (⅜) inch to about one half (½) inch in thickness.
[0095] Although the blocks 23 are positioned adjacent to each other, as shown in FIG. 1B , they are spaced apart from each other by a small distance, to allow the incremental bending of the strip of flat blocks 23 over a complex curve contour 20 of the boat hull 1 . However, these spaces, referred to in the maritime trade as “veins” 24 are vulnerable to exposure to water running therethrough, from cracks or damaged seals in the boat hull 1 or its accessory structures, such as port holes, gunnel molding, weep holes in the anchor area or ventilation holes. Other areas of water intrusion include the motor compartments of the boat. Water further collects in the trough areas of the boat hull 1 , where the complex curves 20 are of such configuration that they cannot be filled by balsa wood blocks 23 .
[0096] The balsa wood cores shown in FIG. 1B before moisture damage thereto, are susceptible to water induced rot, eventually pulverizing and leaving areas having a lack of structural integrity in the areas of damaged and pulverized balsa wood core blocks 23 .
[0097] The prior art generally includes macro cutting of large sections of the damaged balsa wood core areas of blocks 23 underneath the outer fiberglass skin 3 of the boat hull 1 , and surgically removing wholesale sections of balsa wood block aggregates.
[0098] In contrast, as shown in FIGS. 2 and 9 , the present invention uses selectively placed microsurgical incisions, to make minor incisions in the outer fiberglass skin 3 of the boat hull 1 , and selectively targeting the moisture ridden areas of the balsa wood core blocks 23 shown in FIG. 1B before moisture damage thereto between the inner and outer fiberglass layers 3 and 21 of the boat hull 1 .
[0099] First, the boat hull 1 is examined with moisture meters 8 , shown in FIG. 1A , to ascertain the general area of moisture infestation before any cuts are made into the outer boat hull skin 3 . Thermal imaging cameras can also be used.
[0100] Then, as shown in FIG. 2 , a grid region 10 is laid out over the general areas of moisture infestation, and selective cuts are made to identify the exact locations of the moisture ridden core areas of balsa core blocks 23 . As shown in FIG. 5 , holes may be cut, for example, by a hand-held hole drill 60 having a mandrel 61 holding cylindrical serrated, barbed hole saws 62 . Typically the grid region 10 is graphed out by using a grease pencil or other marker and a straight edge, such as a ruler or yardstick. Additionally, the grid pattern can be implemented by optical projections or other similar temporary marking means. The grid region 10 is broken down into discernable sections, labeled by section labels, such as, for example, “A”, “B”, “C”, etc.
[0101] Normally the grid region 10 shown in FIG. 2 is not marked all the way up to the top of the boat hull 1 , because the top portion of a boat hull 1 is normally not infested with water permeation.
[0102] The grid region 10 is dated at locations of significant moisture readings every two or three days during treatment. Moisture readings are repeated during treatment, to ascertain whether moisture content has decreased from wet readings of between twenty and thirty percent concentration, to a relatively dry concentration of less than ten percent moisture content, during treatment of the boat hull 1 with the heating and vacuum system and method of the present invention, whereby vacuum plates 14 are attached with fastening means, such as tape 12 , over openings in the hull 1 to extract moisture from damaged areas via vacuum hoses 11 . As shown in FIG. 3 , vacuum plates 14 include transparent plate portion 30 , such as of polycarbonate, and at least one vacuum hose barb 32 , to which is attached a respective vacuum hose 11 shown in FIG. 2 . An elastomeric seal 31 , such as a closed cell foam gasket, seals vacuum plate 14 upon boat hull 1 .
[0103] Stand-alone vacuum system 35 , shown in FIG. 4 , includes vacuum pump 36 having large vacuum hose 37 attached to vacuum manifold 38 , wherein vacuum gauge 39 indicates vacuum. Vacuum manifold 38 has a plurality of hose barbs 42 , to which are attached vacuum hoses 11 . Unused barbs 42 are capped by seal caps 41 to prevent vacuum leakage through vacuum manifold 38 .
[0104] An overall vacuum and pressure center 45 with vacuum pump 36 , being powered by motor 46 plugged into outlet 53 , is shown in FIG. 4A . Intake line 48 from manifold to vacuum pump attaches to vacuum manifold 38 and drain spigot 47 drains out accumulated water from the air drawn in by vacuum pump 36 . At the boat hull 1 , vacuum hoses 11 are attached to vacuum plates 14 . The pressure supply side obtains compressed air from an external source via compressed air line 56 which is attached to air inlet filter 49 on air tank 50 . Electric heater 54 attached to an electrical power source, such as, for example, outlet 53 , heats the compressed air in tank 50 before it is distributed via compressed air manifold 55 and hoses 51 to line filters 52 . These lead to input openings in the fiberglass hull skin, in the regions of vacuum plates 14 , to aid in drying damaged areas. Compressed air gauge 40 indicates pressure at manifold 55 .
[0105] FIG. 9 shows a typical hole 85 cut through an exterior fiberglass skin of the side of a boat with the hole saw tool shown in FIG. 5 , in the region of a rotted wood core portion 86 of the wood core 20 , shown in FIG. 1B before moisture damage thereto, beneath the exterior fiberglass skin of the boat hull.
[0106] Core samples are taken through the exterior boat hull fiberglass skin, in the vicinity of the sawed holes shown in FIG. 9 . Visual observations are made to see the condition and color of the damaged core sample, to ascertain pulverization and/or rotting of the moisture infested wood blocks, shown in FIG. 1B before moisture damage thereto.
[0107] As shown in FIGS. 6 , 7 and 8 , various straight oriented routing tools ( FIG. 6 ), right angle bent oriented routing tools ( FIG. 7 ) and flexible multidirectional oriented routing tools ( FIG. 8 ) are used to rout out and remove significant chunks and portions of water rooted debris from the damaged wood core portions beneath the exterior fiberglass skin of the boat hull shown in FIGS. 2 , 2 A, 2 B and 9 .
[0108] FIG. 9A shows a flexible auger including a motor suspended by a hook and hanger loop. The motor rotates a cutting tool by producing power through a flexible shaft, similar to those of tools of Dremel Corporation. The flexible shaft is guided through a stiffening sleeve, such as a high durometer elastomeric tubing slipped at the shaft and handpiece remotely inserted through a hole to an inaccessible area beneath the boat hull skin. The stiffening sleeve assists in guiding the normally too flexible shaft. By adding the stiffening sleeve, the collett holding the cutting tool can be remotely manipulated in place for cutting. Alternatively, a bendable outer covering such as used with a gooseneck lamp can be used over the flexible shaft.
[0109] Heat is applied from propane fired hot air heaters through small incisions, similar to incisions for applying vacuum therethrough (as in FIGS. 2 , 3 and 4 ) typically in the top of the damaged area, to dry out the moisture ridden damaged balsa wood core areas 86 of the wood core areas 20 , shown in FIG. 1A , similar to the moisture damaged areas 5 of wood core area 4 of prior art FIG. 1 , before moisture damage thereto.
[0110] As also shown in FIG. 2 , during the selective boat hull drying process, vacuum is selectively applied from below, also through small incisions, to promote drying by facilitating circulation of air within the boat hull.
[0111] As shown in FIGS. 4 and 4A , vacuum force is selective applied under sealed vacuum draw plates 14 having a preferably centrally located vacuum hose barb 32 connectable to a vacuum hose 11 and vacuum power source 36 . The vacuum draw plates 14 are preferably made of transparent but strong materials, such as polycarbonate, and are sealed at respective edges thereof by a gasket 31 , such as, for example, a closed cell foam gasket.
[0112] As shown in FIGS. 2 , 2 A, 2 B, 4 , 4 A and 5 , vacuum can be selectively applied in a number of moisture ridden areas by a plurality of vacuum draw plates 14 attached by respective vacuum hoses 11 to a vacuum gauge-controlled manifold 38 connected by a further vacuum hose 48 to a vacuum power source 36 , such as a commercial electrically powered vacuum pump having an AC power plug and electrical cord.
[0113] While direct cleaning out can be done of the moisture infested balsa wood core areas 86 , with straight or bent electrically or pneumatically powered routing tools operating within the boundaries of the incisions, it is alternatively known that damaged and/or wet balsa wood material can also be removed remotely from beneath the exterior fiberglass skin of the boat hull, by using routing tools shown in FIGS. 8 and 9A , having flexible neck portion conduits 79 or 95 connecting a routing head to a power supply, wherein the flexible conduits 79 or 95 are used to direct the location of routing tool heads 80 at selected locations beneath uncut portions of the exterior fiberglass skin 2 of the boat hull.
[0114] Veining bits are used in straight, angled or flexible necked routing grinder tools (shown in FIGS. 6 , 7 , 8 and 9 A respectively) to remove the damaged balsa wood core blocks shown in FIG. 1B before moisture damage thereto. Butterfly bits and other de-burring bits are used with drills for de-veining and removing damaged core areas.
[0115] After the removal of the damaged core, the dry cleaned cavities are filled and re-packed with a re-sealing epoxy resin having a high density filler, such as chopped glass mill fibers. The resin is applied from a dispenser, such as, for example, a manually operable caulking gun, which injects the epoxy resin into the cavities. Alternatively, the caulking gun may be powered by an air pump.
[0116] The treated areas are sealed first with ferring compound, then a sealant, such as epoxy, vinyl ester, etc., then covered by a gel coat and finally covered by a waterproof barrier coat such as a creamy gel coat and color of finish gel coat. This sealing process is repeated. For cosmetic finishing of the repaired areas, the areas are wet sanded then treated areas are treated with a surface finishing compound, and finished by sanding and wax compounding of the surface, to restore the treated areas to be as smooth and blemish-free as before treatment.
[0117] As noted herein, preventive steps can also be done in accordance with the present invention, to prevent water intrusion and future moisture damage to the boat hull.
[0118] In the foregoing description, certain terms and visual depictions are used to illustrate the preferred embodiment. However, no unnecessary limitations are to be construed by the terms used or illustrations depicted, beyond what is shown in the prior art, since the terms and illustrations are exemplary only, and are not meant to limit the scope of the present invention.
[0119] It is further known that other modifications may be made to the present invention, without departing the scope of the invention, as noted in the appended Claims. | A method for preventive maintenance of a boat hull to restore the integrity of a fiberglass boat hull and prevent new water infiltration damage to a boat hull. The wet area repair guidelines using a surface moisture meter. Any balsa cored area reading 15% or above is considered a wet area. Any wood cored area reading 20% or above is considered a wet area. The preventive maintenance steps involve removing all through-hull fittings or hardware. Wet core areas are then dried out using heat lamps, lights or heaters, hot-vac systems, or octopus vacuum with grid system. If necessary, any area not drying out is de-cored and repaired accordingly. After repairs are finished, all through-hull fillings or hardware is reinstalled using new sealant. | 1 |
BACKGROUND OF THE INVENTION
[0001] 1. Technical Field
[0002] The invention relates generally to reflector ovens used for cooking food in front of an open fire such as a campfire, and more particularly to an improved collapsible reflector oven designed to be light weight and easily portable and suitable to effectively cook food using the same recipes and cooking times as would be used in a conventional kitchen oven.
[0003] 2. Description of Prior Art
[0004] Collapsible reflector ovens are well known in the industry. Several devices employing the basic concept of reflecting the heat energy of an open fire onto food in order to cook the food have been developed, with many of them having the added property of being collapsible for easy storage and portability. These devices are especially attractive to persons enjoying the outdoors where they will be away from conventional cooking means, such as campers, hunters, backpackers, and the like. Examples of collapsible reflector ovens are shown in U.S. Pat. Nos. 216,003 (Watson), 240,639 (Austin), 449,432 (Watson), 548,499 (Ashmore), 1,216,008 (Stonebridge), 2,520,030 (Cliff), 2,543,115 (Lindstaedt), 2,580,925 (Jarvis), 2,757,664 (McDowell), 2,921,577 (Smith), 3,026,866 (Lynch), and 5,983,887 (Bourgeois), the disclosure of each of which is incorporated herein by reference.
[0005] Previous reflector ovens have suffered from various problems, of which each of the successive inventions previously identified attempted to correct. However, the one problem that has never been adequately solved by the prior art is the actual cooking effectiveness of reflector ovens. The reflector ovens represented by the prior art fail to effectively cook food using the same recipes and cooking times as would be used in a conventional kitchen oven. This is largely due to the prior art reflector ovens failing to generate adequate heat and distributing the heat evenly to the food to be cooked. Many of the prior art reflector ovens were configured such that the rear of the ovens terminated in a vertex well behind the location of the food and distant from the energy source, causing much of the reflected energy from the fire to be lost in the rear of the oven. See, e.g., Watson, Austin, Watson, Stonebridge, Cliff, Lindstaedt, Jarvis, McDowell, and Smith. The invention disclosed herein reduces this inefficiency by the oven having a rear panel oriented vertically directly behind the food, thereby directing energy onto the food and the food holder. In addition, many of the prior art reflector ovens made use of shelves to hold the food, which shelves were made of the same reflecting material as the sides of the ovens. See, e.g., Stonebridge, Lindstaedt, McDowell, Smith, Lynch, and Bourgeois. These food-supporting shelves reflect energy away from the bottom of the food to be cooked, resulting in lower overall heating of the food and uneven cooking. Finally, none of the prior art reflector ovens teach the use of a container to hold the food which is constructed of a non-reflecting, energy-absorbing material. The disclosed invention makes use of a food holder constructed of a non-reflecting, energy-absorbing material, which minimizes the wasteful reflection of energy away from the food, and more importantly becomes very hot by absorbing the energy directed therein by the reflective surfaces of the oven. So constructed, the food holder may attain temperatures as much as three times hotter than the air temperature within the oven, achieving temperatures similar to those found in a conventional kitchen oven.
[0006] It is an object of this invention to provide a new and improved reflector oven which retains the ease of use and portability of the prior art but improves upon the quality of the cooking function such that the user may cook foods in front of an open fire using the same recipes and cooking times as would be used in a conventional kitchen oven.
SUMMARY
[0007] In one aspect, the invention is directed to a collapsible reflector oven to be used for cooking in front of an open fire, such as a campfire. The oven comprises a top panel, a bottom panel, a rear panel, a left side panel, a right side panel, and a food holder, whereby the top, bottom, rear, left side, and right side panels are constructed of a metallic material in which at least the inside surface of each panel is reflective, and the food holder is constructed of a non-reflecting, energy-absorbing material. The reflective surfaces of the panels direct heat energy from the fire into the food holder which absorbs the energy, becoming sufficiently hot to cook the food placed therein. The invention permits use of the same recipes and cooking times as would be used in a conventional kitchen oven.
[0008] This aspect may include one or more of the following features: the top and bottom panels are generally rectangular in shape, wider than deep, and of substantially identical dimensions; the rear panel is generally rectangular in shape, substantially the same width as the top and bottom panels but of lesser height; and the left and right side panels are generally trapezoidal in shape, with the front edges of greater height than the rear edges, and of substantially identical dimensions. The five panels are connected to each other along adjacent edges by hinge means, permitting the oven to be folded and unfolded, and the top panel is detachably attached to the two side panels by connection means. The food holder is comprised of a removable container created of a non-reflecting, energy-absorbing material, and two brackets attached to the inner surfaces of the two side panels which support the container in a generally horizontal orientation. The oven may include a handle attached to the top panel for moving the oven while it is in use, for example to regulate the cooking temperature, and may include a support foot attached to the bottom panel to hold the oven in a generally upright position while it is in use.
[0009] Other features and advantages of the invention are described below.
DESCRIPTION OF DRAWINGS
[0010] [0010]FIG. 1 is a perspective front view of the reflector oven in the fully opened position, showing the interior of the oven and the food holder.
[0011] [0011]FIG. 2 is an exploded view of the hinge means connecting two panels.
[0012] [0012]FIG. 3 is a left side perspective view of the reflector oven, showing the handle and support foot and the reflector oven's orientation to a fire.
[0013] [0013]FIG. 4 is a perspective view of the reflector oven in a partially collapsed position.
DESCRIPTION OF THE INVENTION
[0014] [0014]FIG. 1 shows a perspective front view of one embodiment of a reflector oven 1 as it is intended to be used in the fully opened position. The basic components of the reflector oven 1 include a top panel 2 , a bottom panel 3 , a rear panel 4 , a left side panel 5 , a right side panel 6 , and a food holder 7 . The panels are held together by a first connection means 28 , a second connection means 29 , and hinge means 30 . The panels 2 , 3 , 4 , 5 , 6 constituting the reflector oven 1 are constructed of a metallic material in which at least the inside surface of each panel is reflective of the heat energy generated by an open fire 57 . In one embodiment the panels are made of tinned sheet steel. The food holder 7 must include a container 42 constructed of a non-reflecting, energy-absorbing material. In one embodiment the container is a pan 43 made of blackened steel. The reflector oven 1 is used by placing the food 58 to be cooked in the container 42 , placing the container 42 into the reflector oven 1 , and placing the reflector oven 1 with its open front oriented towards an open fire 57 , such as a camp fire. The heat energy of the open fire 57 is reflected by the panels 2 , 3 , 4 , 5 , 6 of the reflector oven 1 and directed towards the food 58 and the container 42 . The container 42 absorbs the energy from the fire 57 and becomes much hotter than the air temperature within the reflector oven 1 , thereby efficiently cooking the food 58 placed therein. The temperature of the reflector oven 1 is regulated by moving it closer or further from the fire 57 . The food cooking properties of the reflector oven 1 are enhanced over the prior art by the use of the non-reflecting, energy-absorbing food holder 7 , which allows for quicker, more even cooking of the food 58 , thus permitting the use of recipes and cooking times devised for food preparation using conventional kitchen ovens.
[0015] The shapes of the panels 2 , 3 , 4 , 5 , 6 enhance the food cooking properties of the reflector oven 1 . The top 2 , rear 4 , and bottom 3 panels are generally rectangular in shape, with a greater width side to side than depth front to back. This permits the reflector oven 1 to present a wider profile to the fire 57 , allowing more of the energy of the fire 57 to be directed into the food holder 7 . The left side panel 5 and right side panel 6 are generally trapezoidal in shape, with their rear edges 21 , 25 shorter then their front edges 20 , 24 and their top and bottom edges 23 , 23 , 26 , 27 substantially equal in length. The top panel 2 and bottom panel 3 are substantially of the same dimensions, and the left side panel 5 and the right side panel 6 are substantially of the same dimensions, thereby creating a generally symmetrical space within the reflector oven 1 above and below the food holder 7 to enhance the even heating and cooking of the food 58 . The rear panel 4 presents a flat surface generally perpendicular to the food holder 7 , allowing energy from the fire 57 to be better directed into the food holder 7 and not lost in the rear of the reflector oven 1 . In one embodiment the top panel 2 is oriented at an angle approximately thirty degrees above the horizontal ascending from the back of the reflector oven 1 to the front, and the bottom panel 3 is oriented at an angle approximately thirty degrees below the horizontal descending from the back of the reflector oven 1 to the front. Other embodiments may orient the top panel 2 and bottom panel 3 at angles slightly greater or lesser than thirty degrees without compromising the effectiveness of the reflector oven 1 .
[0016] The reflector oven 1 is constructed with most of its component parts permanently connected to each other to facilitate ease of set up and collapse. The five panels 2 , 3 , 4 , 5 , 6 are permanently connected to each other along common edges by hinge means 30 , and the left side panel 5 is detachably attached to the top panel 2 by a first connection means 28 and the right side panel 6 is detachably attached to the top panel 2 by a second connection means 29 . The five panels 2 , 3 , 4 , 5 , 6 so connected and attached form a five sided reflector oven 1 . The specific connections points are as follows: the top panel 2 is connected to the rear panel 4 by a hinge means 30 connecting the rear edge 9 of the top panel 2 to the top edge 16 of the rear panel 4 ; the rear panel 4 is connected to the bottom panel 3 by a hinge means 30 connecting the bottom edge 17 of the rear panel 4 to the rear edge 13 of the bottom panel 3 ; the left side panel 5 is connected to the bottom panel 3 by a hinge means 30 connecting the bottom edge 23 of left side panel 5 to the left edge 14 of bottom panel 3 ; and the right side panel 6 is connected to the bottom panel 3 by a hinge means 30 connecting the bottom edge 27 of right side panel 6 to the right edge 15 of bottom panel 3 . With the five panels 2 , 3 , 4 , 5 , 6 so connected by hinge means 30 , they may be positioned to lie flat in an upside down “T” shape, with the top panel 2 , rear panel 4 , and bottom panel 3 forming one axis of the “T” and the left side panel 5 , the bottom panel 3 , and the right side panel 6 forming the other axis of the “T”.
[0017] The reflector oven 1 is readied for use by unfolding the five panels 2 , 3 , 4 , 5 , 6 into the flat “T” position described above. The left side panel 5 and the right side panel 6 are then positioned generally perpendicular to the bottom panel 3 , the rear panel 4 is positioned such that the left edge 18 of the rear panel 4 is adjacent to the rear edge 21 of the left side panel 5 and the right edge 19 of the rear panel 4 is adjacent to the rear edge 25 of the right side panel 6 . Finally, the top panel 2 is positioned such that the left edge 10 of the top panel 2 is adjacent to the top edge 22 of the left side panel 5 allowing the top panel 2 to be attached to the left side panel 5 by the first connection means 28 , and the right edge 11 of the top panel 2 is adjacent to the top edge 26 of the right side panel 6 allowing the top panel 2 to be attached to the right side panel 6 by the second connection means 29 . Once the outer structure of the reflector oven 1 is assembled, the container 42 is placed into the reflector oven 1 .
[0018] The reflector oven 1 is readied for storage by first removing the container 42 from the reflector oven 1 , detaching the first connection means 28 and the second connection means 29 , unfolding the five panels 2 , 3 , 4 , 5 , 6 into the flat “T” position described above, and then folding the left side panel 5 and the right side panel 6 onto the bottom panel 3 and folding the top panel 2 onto both the rear panel 4 and the bottom panel 3 . FIG. 4 shows the reflector oven 1 partially collapsed and indicated how the panels 2 , 3 , 4 , 5 , 6 are to be folded. As so folded, the reflector oven 1 may be placed into a bag for storage 59 , along with the container 42 and the removable components (if any) of the first and second connection means 28 , 29 .
[0019] In one embodiment, the first connection means is formed into the left edge 10 of the top panel 2 and the top edge 22 of the left side panel 5 . One or more flanges 31 extend from the left edge 10 of the top panel 2 and are curved back towards the left edge 10 of the top panel 2 , forming a like number of cylindrical sleeves 32 . Similarly, one or more flanges 31 extend from the top edge 22 of the left side panel 5 and are curved back towards the top edge 22 of the left side panel 5 , forming a like number of cylindrical sleeves 32 . Each cylindrical sleeve 32 is open at either end and has a uniform inside diameter. The internal axis of each cylindrical sleeve 32 is substantially aligned along the edge of the panel on which it is situated. The cylindrical sleeves 32 are situated along the left edge 10 of the top panel 2 and along the top edge 22 of the left side panel 5 in an alternating manner such that when the left edge 10 of the top panel 2 is positioned adjacent to and aligned with the top edge 22 of the left side panel 5 , the individual cylindrical sleeves 32 align with each other end to end forming a continuous cylindrical aperture. A first connection pin 33 is then inserted into the cylindrical sleeves 32 , thereby retaining the top panel 2 firmly in connection with the left side panel 5 . The first connection pin 33 has a generally straight shaft 34 and has a shaped end 35 . The length of the shaft 34 is just slightly longer than the length of the left edge 10 of the top panel 2 and the diameter of the shaft 34 is just slightly less than the inside diameter of the cylindrical sleeves 32 . The shaped end 35 of the first connection pin 33 may be of any suitable shape, such that it stops the shaped end 35 of the first connection pin 33 from completely passing through the cylindrical sleeves 32 . In one embodiment, the first connection pin 33 has a shaped end 35 in the shape of an eye-hook, facilitating easy grasping, and its opposite end is tapered 36 , facilitating insertion of the first connection pin 33 into the cylindrical sleeves 32 . The second connection means 29 is substantially identical to the first connection means 28 , except that it is formed into the right edge 11 of the top panel 2 and the top edge 26 of the right side panel 6 . Other embodiments of the first and second connection means 28 , 29 may be used without departing from the subject or spirit of the invention.
[0020] [0020]FIG. 2 shows one embodiment of the hinge means 30 . In this embodiment, each hinge means 30 is formed into the adjacent edges of each pair of panels. One or more flanges 38 extend from the adjacent edge of the first panel in the pair and are curved back towards that edge, forming a like number of cylindrical hinge sleeves 39 . Similarly, one or more flanges 38 extend from the adjacent edge of the second panel in the pair and are curved back towards that edge, forming a like number of cylindrical hinge sleeves 39 . Each cylindrical hinge sleeve 39 is open at either end and has a uniform inside diameter. The internal axis of each cylindrical hinge sleeve 39 is substantially aligned along the edge of the panel on which it is situated. The cylindrical hinge sleeves 39 are situated along the adjacent edge of the first panel in the pair and along the adjacent edge of the second panel in the pair in an alternating manner such that when the adjacent edge of the first panel in the pair is positioned adjacent to and aligned with the adjacent edge of the second panel of the pair, the individual cylindrical hinge sleeves 39 align with each other end to end forming a continuous cylindrical aperture. A hinge pin 40 is then inserted into the cylindrical hinge sleeves 39 , thereby retaining the pair of panels hingedly in connection with each other. The hinge pin 40 has a generally straight shaft 41 and is just slightly shorter than the length of the edge of the panels on which the cylindrical hinge sleeves 39 are situated. The diameter of the shaft 41 is just slightly less than the inside diameter of the cylindrical hinge sleeves 39 . The open ends of the two cylindrical hinge sleeves 39 forming the ends of the continuous cylindrical aperture are crimped to retain the hinge pin 40 within the continuous cylindrical aperture. Other embodiments of the hinge means 30 may be used without departing from the subject or spirit of the invention.
[0021] [0021]FIG. 1 shows one embodiment of the food holder 7 . In this embodiment, the food holder 7 is comprised of a removable container 42 and two brackets 44 , 47 attached to the inside surfaces of the left and right side panels 5 , 6 . The left bracket 44 is angled approximately ninety degrees, thereby having a first plane 45 and a second plane 46 oriented approximately ninety degrees to each other. The first plane 45 of the left bracket 44 is attached to and flush with the inside surface of the left side panel 5 and situated slightly below a point midway between the top and bottom edges 22 , 23 of the left side panel 5 . The left bracket 44 is oriented such that the second plane 46 of the left bracket 44 forms a generally horizontal shelf extending into the interior of the reflector oven 1 . The width of the left bracket 44 is less than the width of the left side panel 5 . The right bracket 47 is generally of the same shape and dimension as the left bracket 44 , and is situated at point on the inside surface of the right side panel 6 corresponding to the location of the left bracket 44 on the left side panel 5 . In one embodiment the brackets 44 , 47 are attached to the left and right side panels 5 , 6 by pop rivets 50 . The food holder 7 is readied for use by placing the container 42 upon the second plane 46 of the left bracket 44 and the second plane 49 of the right bracket 47 . In one embodiment the container 42 is a generally rectangular pan 43 with a substantially flat bottom, vertical sides, and open at the top, having a length slightly less than the width of the top panel 2 and a width slightly less than the width of the left side panel 5 . Other embodiments of the food holder 7 may be used without departing from the subject or spirit of the invention, except that the container 42 must be constructed of a non-reflecting, energy-absorbing material.
[0022] [0022]FIG. 3 shows a left side perspective view of the reflector oven 1 and an embodiment of the invention using a handle 51 . The handle 51 is used to position the reflector oven i with respect to the fire 57 , thereby regulating the cooking temperature. In this embodiment, the handle 51 is attached to the top panel 2 . The handle 51 may also be foldable, so that it lies flat against the top panel 2 when not in use for easier storage. In the embodiment shown, the handle 51 is comprised of a rectangular grip 52 composed of a heavy gauge metal wire and an attachment plate 53 . The attachment plate 53 has a generally rectangular shape and is folded against itself, with the fold having a generally cylindrical shape in which to contain one side of the rectangular grip 52 . The fold of the attachment plate 53 accommodates the rectangular grip 52 snugly, such that the rectangular grip 52 may be pivoted by an application of minimal force but will not flop about on its own. In one embodiment the attachment plate 53 is attached to the top panel 2 by pop rivets 50 . Other embodiments of the handle 51 may be used without departing from the subject or spirit of the invention.
[0023] [0023]FIG. 3 also shows an embodiment of the invention using a support foot 54 . The support foot 54 is used to support the rear of the reflector oven 1 off the ground such that the reflector oven 1 will have a generally upright orientation and the container 42 will have a generally horizontal orientation. In this embodiment, the support foot 54 is attached to the bottom panel 3 . The support foot 54 may also be foldable, so that it lies against the bottom panel 3 when not in use for easier storage. In the embodiment shown, the support foot 54 is comprised of a rectangular foot 55 composed of a heavy gauge metal wire and an attachment plate 56 . The rectangular foot 55 has a first long side 55 A and a second long side 55 B opposite the first long side 55 A and of substantially identical length to the first long side 55 A and a first short side 55 C and a second short side 55 D opposite the first short side 55 C and of substantially identical length to the first short side 55 C. The attachment plate 56 has a generally rectangular shape and is folded against itself, with the fold having a generally cylindrical shape in which to contain the first long side 55 A of the rectangular foot 55 . The fold of the attachment plate 56 accommodates the rectangular foot 55 snugly, such that the rectangular foot 55 may be pivoted by an application of minimal force but will not flop about on its own. In this embodiment the rectangular foot 55 is angled substantially ninety degrees along its first short side 55 C and its second short side 55 D, with the angle being situated along the first and second short sides 55 C, 55 D at substantially the same distance from the first long side 55 A and closer to the first long side 55 A than to the second long side 55 B. The angled first and second short sides 55 C, 55 D are oriented in the same direction, towards the front of the reflector oven 1 . When the rectangular foot 55 is pivoted upward and forward, the second long side 55 B comes in contact with the bottom panel 3 , causing the support foot 54 to be relatively flat against the bottom of the reflector oven 1 . When the rectangular foot 55 is pivoted downward and rearward, the angle of the rectangular foot 55 comes in contact with the bottom panel 3 , resulting in the portion of the rectangular foot 55 located along the first and second short sides 55 C, 55 D between the angle and the second long side 55 B to be oriented in a generally downward position. The attachment plate 56 may be attached to the bottom panel 3 by pop rivets 50 . Other embodiments of the support foot 54 may be used without departing from the subject or spirit of the invention.
[0024] In one embodiment, the front edge 8 of the top panel 2 , the front edge 12 of the bottom panel 3 , the front edge 20 of the left side panel 5 , and the front edge 24 of the right side panel 6 are rolled back onto themselves forming rounded edges. These rounded edges prevent users of the reflector oven 1 from cutting themselves along the sharp exposed edges and also provide rigidity to the reflector oven 1 . Similarly, the left edge 18 of the rear panel 4 , the right edge 19 of the rear panel 4 , the rear edge 21 of the left side panel 5 , and rear edge 25 of the right side panel 6 are folded onto themselves forming hemmed edges. These hemmed edges prevent users of the reflector oven 1 from cutting themselves along the sharp exposed edges.
[0025] Modifications and variations can be made to the disclosed embodiments of the invention without departing from the subject or spirit of the invention as defined in the following claims. | A collapsible reflector oven to be used for cooking in front of an open fire, such as a campfire, constructed of various panels having reflective inside surfaces and a food holder constructed of a non-reflecting, energy-absorbing material. The reflective surfaces of the panels direct heat energy from the fire into the food holder which absorbs the energy, becoming sufficiently hot to properly cook the food placed therein using the same recipes and cooking times as would be used in a conventional kitchen oven. The reflector oven may be collapsed for storage and unfolded for use. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This is a Continuation-In-Part of co-pending application Ser. No. 09/845,399 filed Apr. 30, 2001 which is a Continuation-In-Part of co-pending Ser. No. 09/605,763 filed Jun. 28, 2000 now U.S. Pat. No. 6.382,528 which is a Continuation-In-Part of co-pending Ser. No. 09/435,965 filed Nov. 8, 1999 now U.S. Pat. No. 6,089,468, all of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to injection molding machines for the transmission of various molten materials to a mold cavity or cavities. More specifically, this invention relates to a method and apparatus for the insertion of a mixer in the melt stream of an injection molding machine.
2. Summary of the Prior Art
The large number of variables in the injection molding process creates serious challenges to creating a uniform and high quality part. These variables are significantly compounded within multi-cavity molds. Here we have the problem of not only shot to shot variations but also variations existing between individual cavities within a given shot.
Shear induced flow imbalances occur in all multi-cavity molds that use the industry standard multiple cavity “naturally balanced” runner system whereby the shear and thermal history within each mold is thought to be kept equal regardless of which hot-runner path is taken by the molten material as it flows to the mold cavities. These flow imbalances have been found to be significant and may be the largest contributor to product variation in multi-cavity molds.
Despite the geometrical balance, in what has traditionally been referred to as “naturally balanced” runner systems, it has been found that these runner systems can induce a significant variation in the melt conditions delivered to the various cavities within a multi-cavity mold. These variations can include melt temperature, pressure, and material properties. Within a multi-cavity mold, this will result in variations in the size, shape and mechanical properties of the product. Though the effect is most recognized in molds with eight or more cavities, it can create cavity to cavity variations in molds with as few as two cavities.
The flow imbalance in a mold with a geometrically balanced runner is created as a result of shear and thermal variations developed across the melt as it flows through the runner. The melt in the outer region (perimeter) of the runner's cross-section experiences different shear and temperature conditions than the melt in the center region. As flow is laminar during injection molding, the position of these variations across the melt stream is maintained along the length of the runner branch. When the runner branch is split, the center to perimeter variation becomes a side to side variation after the split. This side to side variation will result in variations in melt conditions from one side to the other of the part molded from the runner branch.
If the runner branches were to split even further, as in a mold with 4 or more cavities, there will exist a different melt in each of the runner branches. This will result in variations in the product created in each mold cavity. It is important to note that as consecutive turns and/or splits of the melt channel occur, the difference in melt temperature and shear history is further amplified. This cumulative effect is clearly recognized in large multi-cavity molds where the runner branches split and turn many times.
In an attempt to reduce this variation, the prior art has been primarily directed at various mixing devices that are located within the runner nozzle which is typically just prior the mold cavity. Examples of this can be found in U.S. Pat. No. 4,965,028 to Manus et al. and U.S. Pat. No. 5,405,258 to Babin.
Mixers at various locations within the injection molding machine are also well known. Examples of mixers in the hot runner manifold include U.S. Pat. No. 5,683,731 to Deardurff et al., European Patent 0293756, U.S. Pat. No. 5,688,462 to Salamon et al. and U.S. Pat. No. 4,848,920 to Heathe et al. (all incorporated herein by reference). An example of mixers installed within the injection unit can be found in U.S. Pat. No. 3,156,013 to Elphee (incorporated herein by reference).
Within the prior art, at least as much as known, there is no retrofit apparatus or method for installation of a mixer in an already existing injection molding machine, specifically in the hot runner manifold. Attempts at alleviating runner imbalance has been directed at correcting the problem within the injection nozzle or further upstream in the machine nozzle or sprue bar.
There exists a need for a mixer apparatus and method that allows for the easy and precise placement of a mixer in the melt stream in an injection molding machine, for example in a hot runner subsystem. Preferably, the mixer should be installed just upstream of where the melt channel splits or divides.
SUMMARY OF THE INVENTION
One general objective of the present invention is to provide a mixer apparatus and method that can be easily and precisely placed in an injection molding machine to help alleviate non-homogenity in a melt stream.
Another general object of the present invention is to provide a replaceable mixer insert apparatus and method in an injection molding machine.
Yet another general object of the present invention is to provide a mixer apparatus and method that is completely contained within the hot runner manifold.
The foregoing objects are achieved in one exemplicative embodiment by providing a mixer insert that is sealing placed in a receiving bore, for example, in a hot runner manifold. The mixer insert contains a mixing element that is held in alignment with and communicates with a melt channel. As the non-homogeneous melt flows through the mixing element it is mixed and homogenized thereby reducing melt stream imbalances.
Further objects and advantages of the present invention will appear hereinbelow.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 a - 1 c are simplified cross-sectional views of an exemplicative embodiment of the present on;
FIG. 2 is an enlarged cross-sectional view of an exemplicative embodiment of the present invention;
FIG. 2 a is an end view of the elongated torpedo;
FIG. 3 is a simplified cross-sectional view of a second exemplicative embodiment of the present invention;
FIG. 4 is a simplified cross-sectional view of a third exemplicative embodiment of the present invention;
FIG. 4 a is a simplified cross-sectional view of a fourth exemplicative embodiment of the present invention;
FIG. 4 b is a simplified cross-sectional view of a fifth exemplicative embodiment of the present invention;
FIG. 5 is a simplified cross-sectional view of a sixth exemplicative embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring first to FIGS. 1 a - 1 c , cross-sectional views of an exemplicative embodiment of the present invention are shown. A mixer assembly 10 is sealingly inserted into a manifold bore 26 which is formed in a hot runner manifold 12 . Mixer assembly 10 is comprised of a mixer insert 18 , which in a preferred embodiment is comprised of a metallic cylindrical bushing with optional flanges 19 protruding from a top surface of the insert 18 . An insert passageway 24 is formed in the mixer insert 18 perpendicular to its longitudinal axis for receipt of a mixing element 13 . The insert passageway 24 aligns with and communicates with a melt channel 16 when the mixer assembly 10 is fully seated in the manifold 12 . It should be noted that while the embodiments described herein are directed at cylindrically shaped mixer inserts 18 , one skilled in the art could easily provide myriad alternative embodiments comprising various shapes, attachment means and mixing elements therein. All such variations are fully contemplated by the present invention.
As shown in FIG. 1 b , the insert passageway 24 is a stepped bore, with one portion sized to receive and retain a mixing element 13 . For illustrations purposes only and not by limitation, the mixing element 13 in this embodiment is comprised of a torpedo 20 which is co-axially inserted in a mixer bushing 22 . The mixer bushing 22 is also retained in the insert passageway 24 . In a preferred embodiment, the torpedo 20 and the mixer bushing 22 are press fit in the insert passageway 24 . This helps to reduce leakage around the mixer, however, such a retaining means may not be necessary due to the manner in which the mixer bushing and torpedo are already retained inside the mixer insert 18 . Mixing element 13 could easily be modified by one skilled in the art to be any of the known static melt mixers.
An optional seal 40 may be provided around the periphery of the mixer insert 18 to reduce or eliminate the leakage of any molten material. An optional fastener 30 is provided to retain the insert 18 in the manifold 12 . In a preferred embodiment the fastener 30 is threaded into a threaded bore 28 located in the mixer insert 18 to rigidly affix the mixer assembly 10 in the manifold 12 . An optional alignment feature 42 is provided to maintain the alignment of the entrance 20 a with the melt channel 16 . In a preferred embodiment, the alignment feature 42 is a pin press fit into the manifold 12 that interfaces with one of the flanges 19 . Alternatively, flat edges on the flanges 19 could be used for alignment through insertion of the flanges into a appropriately shaped pocket in the manifold 12 .
As shown in FIG. 1 a , the mixer assembly 10 is placed in various locations in the hot runner manifold 12 . The melt enters the manifold 12 at melt inlet 14 and splits into melt channels 16 . Melt channel 16 communicates with an entrance 20 a of the mixer assembly 10 and the molten material is forced through the mixer bushing 22 where exit 20 b further communicates with a second melt channel 32 . Second melt channel 32 further splits into a plurality of third melt channels 34 . Plugs 36 and 38 are affixed in manifold 12 to direct the molten material through the manifold 12 . Preferably, as shown in FIG 1 a , the mixer assembly 10 is installed just before the melt channel splits. This placement helps reduce the melt flow imbalances that adversely impact the quality of a molded part.
Referring now to FIGS. 2 and 2 a , which shows an enlarged cross-sectional view in accordance with one preferred embodiment in accordance with the present invention where like features have like numerals. The mixer bushing 22 has at least one helical groove 50 formed therein running from an inlet 60 to the outlet 62 for communication of the fluid through the mixer assembly 10 . An elongated torpedo 20 is inserted into the mixer bushing 22 and is maintained in a preferably coaxial position by at least one land 54 formed between the helical groove 50 . Adjacent the flow inlet 60 , the torpedo 20 is comprised of an annular disk 58 which abuts against one end of the mixer bushing 22 . A plurality of spokes 64 extend from the center of the torpedo 20 to annular disk 58 , thereby creating space for the flowing melt as it enters the mixer assembly 10 . As the helical groove 54 and lands 56 travel along the direction of the melt flow, a gap 51 which increases in the direction of the melt flow, is formed between the elongated torpedo 20 and the mixer bushing 22 . The cross-sectional area of the helical groove 50 also decreases in the direction of the melt flow.
As the melt travels through mixer bushing 22 , more and more of the melt gradually spills out of the helical groove 50 and over lands 54 such that the melt flow transitions from all helical to all annular flow. This mixing action has been shown to substantially eliminate flow imbalances that occur inside a melt stream.
Referring to FIG. 3, (where like features have like numerals) a second embodiment 100 of the mixer assembly in accordance with the present invention is generally shown. In this embodiment, the mixer insert 18 is attached to the side of a typical hot runner manifold 12 after a 90-degree turn of melt channel 16 . In a preferred embodiment, a plurality of fasteners 30 a and 30 b are inserted through a respective hole in flange 19 and affixed to manifold 12 for retention of the mixer insert 18 .
Referring to FIG. 4 (where like features have like numerals), a third preferred embodiment 200 in accordance with the present invention is generally shown. In this embodiment, and similar to second embodiment 100 , the mixer insert 18 is placed in the manifold bore 26 which is formed through a side of the manifold 12 . The mixer insert 18 has an additional melt passageway 25 formed therein at 90 degrees from the insert passageway 24 thereby forming a 90 degree corner in the mixer insert 18 downstream from the mixer bushing 22 . Optionally, a plurality of fasteners 30 a and 30 b are used to affix the mixer assembly 200 in the manifold 12 .
Referring now to FIG. 4 a (where like features have like numerals), a fourth embodiment 200 a in accordance with the present invention is generally shown. In this embodiment, the insert melt passageway 25 is in fluid communication with multiple second melt channels 32 . As such, the branching of the melt channel 16 occurs within the mixer insert 18 rather than in the manifold 12 .
Referring now to FIG. 4 b (where like features have like numerals), a fifth embodiment 200 b in accordance with the present invention is generally shown. In this embodiment a spring element 39 abuts the mixer insert 18 and is held thereon by a cap 41 which is affixed to the manifold 12 . In the preferred embodiment, the cap 41 has a flange 19 and an optional seal 40 to reduce leakage. The spring element 39 in the preferred embodiment is a belleville type disc spring, but could easily be made from any suitable resilient material. The use of the spring element 39 reduces the need for tight tolerance parts that would normally be required to provide a reliable seal against the high pressure melt. The spring element 39 allows for the cap 41 to sealing seat on a surface of the manifold 12 while also providing a compressive force between the mating surfaces, (for example surface 60 a , 60 b and 60 c ) to prevent or substantially reduce leakage of the high pressure melt therebetween.
Referring now to FIG. 5 (where like features have like numerals), a sixth preferred embodiment 300 in accordance with the present invention is generally shown. In this embodiment, the mixer insert 18 is inserted from a top surface of manifold 12 and provides a 90 degree turn just upstream of the mixer entrance 20 a where melt passageway 25 interfaces with torpedo 20 . The annular disk 58 of the elongated torpedo is retained between the mixer insert 18 and the mixer bushing 22 . It should be noted that in this embodiment, the mixer bushing 22 is not retained in the mixer insert 18 but rather is seated in the manifold bore 26 and abuts against the annular disk 58 of the torpedo 20 . Again, an optional plurality of fasteners 30 a and 30 b are provided to retain the mixer insert 18 in the manifold 12 which in turn secures the torpedo 20 and mixer bushing 22 in alignment with the melt channel 16 .
It should be noted that while the foregoing description provided only a single description for a mixing element, one skilled in the art could easily envision alternative mixing element arrangements, and as such, all such mixing element embodiments are fully contemplated within the scope of the present invention.
As can be seen, a mixer assembly is provided in accordance with the present invention that may easily and reliable be inserted at various points along a melt channel. Various configurations have been shown that allow insertion of a mixer into a hot runner subsystem that may be replaced or allow for insertion of alternate mixer bushing types to accommodate various molding parameters.
It is to be understood that the invention is not limited to the illustrations described herein, which are deemed to illustrate the best modes of carrying out the invention, and which are susceptible to modification of form, size, arrangement of parts and details of operation. The invention is intended to encompass all such modifications, which are within its spirit and scope as defined by the claims. | A mixer method and apparatus for use generally in injection molding machines is provided. The apparatus and method is generally comprised of a mixer insert that retains a mixing element that is sealingly inserted in the injection molding machine, for example a hot runner manifold. The mixing element reduces the melt imbalances in a flowing melt stream for the formation of improved molded parts. | 1 |
FIELD OF THE INVENTION
The invention relates to a method for the purification of water, more especially condensate originating from a composting process and to the use of a bioreactor for performing such a method. The invention furthermore relates to a method for the composting of organic materials and to an apparatus for the performance of this method.
BACKGROUND OF THE INVENTION
The German patent publication 3,637,393 C, the German patent publication 3,811,399 A and the German patent publication 2,541,070 A disclose composting methods, in which organic materials, more particularly those containing waste materials (or "biowaste"), are composted. More particularly the said German patent publication 3,637,393 C, describes a method and an apparatus, in which organic materials are composted in a sealed container using forced ventilation.
In the prior art composting methods exhaust air purification takes place, with the production of water, since on falling below the dew point on cooler surfaces water vapor entrained in the air and originating from the biological reaction or, respectively, conversion is condensed out.
The composting of kitchen and garden waste, which has been separately handled in the garbage collection service, leads to the release of substantial quantities of water. When the hot exhaust air has cooled down so far that no odors escape into the atmosphere, condensate is produced. So far exhaust air from biological processes, more particularly from composting processes, has been passed through biological filters for reducing the odor fraction, the humidity water being substantially caused to precipitate, this meaning that the filters became clogged on the inlet side. The liquid then produced, which is hard to dispose (also named "percolating water") is heavily contaminated owing to the contact with the biomass and accordingly possessed a very high oxygen requirement (a CSB of approximately 40,000 to 80,000 mg O 2 /l). As a consequence of technical developments filters were provided with upstream cooling traps or scrubbers so that the liquid no longer came into contact with the biomass, in order to reduce the CSB (chemical oxygen requirement) value and the BSB (biochemical oxygen requirement) value of the condensate. The CSB values then resulting amounted approximately to 5,000 mg O 2 /l. This value as well is however still in need of improvement.
SUMMARY OF THE INVENTION
One object of the invention is to provide a method for the purification of water, more particularly condensate resulting from a composting process, with which such purification action may be improved upon.
In accordance with the invention this aim is to be achieved by cleaning the water in a bioreactor, more particularly a high performance bioreactor.
Preferably the water is brought into contact with oxygen, preferably atmospheric oxygen, in the bioreactor and/or agitated.
The water is preferably filtered. It is an advantage if the water is ultra-filtered, for example in an ultra-filtration module.
The composition of the water to be purified is preferably so altered that a biological clarification process is possible.
Preferably the active substances, which determine the oxygen requirement, in the water to be purified are measured. In accordance with a further advantageous development the active substances to be removed from the water are set. This is preferably by measurement of the active substances, on which the oxygen requirement depends, in the water to be purified. A further advantageous development of the invention is characterized in that by inoculating the water to be purified the course of the metabolic functions of the microorganisms, which are introduced, is set. After this the individual substrate parameters (as for example oxygen, carbon, nitrogen, phosphorus, pH value and/or temperature) and the changes resulting therefrom in the metabolic functions may be ascertained. Preferably, the water borne active substances set are filtered from the water. A further advantageous development is characterized in that control of the metabolic functions in the bioreactor is performed by the introduction of oxygen, more particularly atmospheric oxygen and/or the introduction of nutrients and/or by control of the pH value and/or by control of temperature.
Preferably the control of the filtering action, more especially the diaphragm filter action, is by pressure control and/or control of the overflow rate.
The invention furthermore contemplates the use of a bioreactor, more especially a high performance bioreactor, for the performance of the novel method for the purification of water.
The invention furthermore contemplates a method for composting organic materials, more particularly for composting waste, which contains organic materials (or biowaste). Such composting is preferably performed in a sealed container with the use of forced ventilation.
The above mentioned aim is achieved in accordance with the invention in the case of such a method because the organic materials are composted and because the water then produced, more especially in the form of condensate, is purified using the method of the invention for the purification of water.
Preferably the exhaust air from the bioreactor is returned to the said composting ventilation circuit. The exhaust air from the bioreactor is produced more particularly owing to the mixing of the content of the bioreactor with oxygen or respectively atmospheric oxygen.
In accordance with a further advantageous further development the overflow mud, which collects, more particularly in the bioreactor, is composted. Preferably such overflow mud is composted together with the materials to be composted.
The invention furthermore contemplates an apparatus for the performance of the method in accordance with the invention for composting organic materials. In order to attain the above mentioned aim such an apparatus is characterized in accordance with the invention by a container, more particularly a sealed container, provided with forced ventilation means, for composting organic materials and by a bioreactor, more especially a high performance bioreactor, for the purification of the water then produced.
An advantageous further development of such an apparatus is characterized by a filter, more particularly an ultra-filtration module.
BRIEF DESCRIPTION OF THE DRAWINGS
One working embodiment of the invention will now be described in the following with reference to the accompanying drawings.
FIG. 1 shows a diagram of an apparatus for composting organic materials.
FIG. 2 shows changes in the amount of water condensate as function of time.
FIG. 3 shows changes in the composition of the condensate as a function of rotting down time.
DETAILED DESCRIPTION OF THE INVENTION
In the container (aerobic fermenter) 1 organic waste or, respectively, waste which contains organic components, is composted. It is a question of a sealed container with forced ventilation means. The exhaust air is supplied to an exhaust air cleaning plant 2, in which the exhaust air is cooled down so that the water contained in the exhaust air condenses out. The condensate 3 is supplied to high performance bioreactor 4 in which the active substances contained in the water or, respectively, in the condensate are biologically degraded. The water or, respectively, the condensate is therefore purified in the bioreactor 4.
The quantities of water flowing into the bioreactor are dependent on the intensity of metabolism of the rotting mixture present in the container 1. These quantities of water may be seen by way of example in FIG. 2. In FIG. 2 the quantities of water condensate, i. e. the quantities of condensed water, which collects in the air purification unit and is supplied to the bioreactor, are plotted as a function of time. As shown in FIG. 2, the quantity of condensate water changes in the course of the rotting down process. Initially it increases until after about 1.5 to 2.5 days of rotting it reaches its maximum and then goes down again, a renewed increase being possible in some cases. After approximately 6.5 days of rotting the rotting process is terminated. As shown in FIG. 2, the maximum quantity of condensed water in the selected example is in a range of 800 to 1,800 liters. In FIG. 2 four curves are represented, each curve respectively representing changes in a particular rotting container.
The water borne active substances present in the condensate are represented in FIG. 3 as a function of time. The values for CSB in mg/l, electrical conductivity in μS/cm, pH and ammonium concentration in mg/l are plotted. The CSB value is represented by triangles, the electrical conductivity by the squares stood on their apices, the pH value by the filled (black) squares and the ammonium concentration by the unshaded (white) squares. The CSB value is at a maximum at the start of the composting process and then goes down. Electrical conductivity is initially low. After around five days of rotting it reaches a maximum and then drops again. The pH value increases during entire rot time at a slow rate. The ammonium concentration is initially low. It increases and after about four to five days of rotting reaches a maximum. After this it goes down again.
The liquid or, respectively, the water in the bioreactor 4 is mixed with oxygen, preferably atmospheric oxygen and agitated. Accordingly biological and mechanical purification takes place. The water is furthermore supplied by a pump 5 to an ultra-filtration module 6 where it is ultra-filtered. In the ultra-filtration module 6 a diaphragm filter is provided. The water purified by the diaphragm filter, i. e. the filtrate, is supplied to a collecting container (buffer container) 7, from which it may then be removed for use. The filter cake is returned via the line 8 to the bioreactor.
The control of the metabolic processes occurring in the high performance bioreactor 4 is by control of the oxygen input rate, and more particularly of the input rate of atmospheric oxygen, of the rate of input of nutrients, of the pH value and of temperature. The exhaust air resulting from the introduction of oxygen is returned via the line 9 to the ventilation air circuit of the composting system for further purification. The line 9 consequently runs to the container 1.
The control of the rate of operation of the diaphragm filter, that is to say the rate of operation of the ultra-filtration module 6 is by control of the pressure and of the overflow rate. The overflow mud collecting in the system is swilled off from time to time and supplied via the line 10 to the mixture undergoing rotting or composting. The line 10 consequently also leads to the container 1, this not being shown in FIG. 1.
As shown in FIG. 1, a line 11 controlled by a valve is provided, which branches off from the condensate line 3 and from which a sample of condensate may be taken. Furthermore there is a line 12 with a control valve thereon, through which a water sample may be taken from the bioreactor 4. A further line 13 runs from the collecting container 7 back to the ultra-filtration module 6, on which there is a pump 14 and a shut off valve 15. The line 13 serves for reverse swilling of the ultra-filtration module.
From the line, which extends from the ultra-filtration module 6 to the collecting container 7, there branches a further line 16, which is controlled by a gate valve and through which a sample of the filtrate coming from the ultra-filtration module may be taken.
The water present in the collecting container 7 may be drawn off through a line, which is controlled by a gate valve. It may be introduced into a cooling circuit or a duct for dirty water.
The active substances significant for the oxygen requirement in the condensate 3 are able to be exactly measured. The invention is based on the discovery made by Justus von Liebig that "the minimum amount of nutrient determines yield". Related to the present invention this will mean that the composition of the condensate must be so altered that biological clarification is feasible, that is to say by control of the yield of bioreactor it is possible to set the active substances to be separated out. Such active substances are therefore initially set and then filtered out of the water. The setting of the water borne active substances on which the CSB value or, respectively, of the BSB value is dependent, in microorganisms is controlled by inoculation of the condensate to set the course of metabolic functions of the microorganisms introduced. After this the individual substrate parameters (as for example oxygen, carbon, nitrogen, phosphorus, the pH value and temperature) and the changes in metabolic functions resulting therefrom may be ascertained. Since the minimum nutrient factor present determines the yield, it is legitimate to assume that this notion may be extended to apply to the "growth factor" i. e. the "substrate parameter factor". Putting this into practice is by means of control technology. Since the supply of nutrients to a biozone also requires the swilling out of biomass in the course of formation, diaphragm filtration is employed to ensure that sufficient biomass is always retained as is necessary for maintaining optimum metabolic functions. This biomass is swilled back into the high perform biological system, i. e. into the high performance bioreactor.
The method of operation described in the present embodiment of the invention renders it possible to so improve the quality of the water that the condensate may be utilized as technical quality water for open evaporation circuits (for example for cooling exhaust air from biological processes). | In a sealed container, organic material, more especially biowaste is composted. The exhaust air from the sealed container is purified in an exhaust air cleaning unit. In order to improve the cleaning effect, the condensate water from the exhaust air cleaning unit is supplied to a high performance bioreactor, in which it is brought into contact with atmospheric oxygen and is agitated. The suspension leaving from the bioreactor is caused to flow in a circuit through an ultra-filtration module for purifying the water. | 8 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] Not applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
FIELD OF THE INVENTION
[0003] The present invention relates to a method and system for locating an anomaly and in particular to finding the direction and distance to a resistive or conductive anomaly in a formation surrounding a borehole in drilling applications.
BACKGROUND OF THE INVENTION
[0004] In logging while drilling (LWD) geo-steering applications, it is advantageous to detect the presence of a formation anomaly ahead of or around a bit or bottom hole assembly. While currently available techniques are capable of detecting the presence of an anomaly, they are not capable of determining the location of the anomaly with sufficient depth or speed.
[0005] In formation evaluation, the depth of investigation of most logging tools, wire line or LWD has been limited to a few feet from the borehole. One such tool is disclosed in U.S. Pat. No. 5,678,643 to Robbins, et al. U.S. Pat. No. 5,678,643 to Robbins, et al. discloses an LWD tool for locating an anomaly. The tool transmits acoustic signals into a wellbore and receives returning acoustic signals including reflections and refractions. Receivers detect the returning acoustic signals and the time between transmission and receipt can be measured. Distances and directions to detected anomalies are determined by a microprocessor that processes the time delay information from the receivers. As set forth above, the depth of investigation facilitated by the tool is limited.
[0006] Another technique that provides limited depth of investigation is disclosed in U.S. Pat. No. 6,181,138 to Hagiwara. This technique for locating an anomaly utilizes tilted coil induction tools and frequency domain excitation techniques. In order to achieve a depth of investigation with such a tool, a longer tool size would be required. However, longer tools generally result in poor spatial resolution.
[0007] In order to increase depth capabilities, transient electromagnetic (EM) methods have been proposed. One such method for increasing the depth of investigation is proposed in U.S. Pat. No. 5,955,884 to Payton, et al. The tool disclosed in this patent utilizes electric and electromagnetic transmitters to apply electromagnetic energy to a formation at selected frequencies and waveforms that maximize radial depth of penetration into the target formation. In this transient EM method, the current is generally terminated at a transmitter antenna and temporal change of voltage induced in a receiver antenna is monitored. This technique has allowed detection of an anomaly at distances as deep as ten to one hundred meters. However, while Payton discloses a transient EM method enabling detection of an anomaly, it does not provide a technique for determining the direction of the anomaly.
[0008] Other references, such as PCT application WO/03/019237 also disclose the use of directional resistivity measurements in logging applications. This reference uses the measurements for generating an image of an earth formation after measuring the acoustic velocity of the formation and combining the results. This reference does not disclose a specific method for determining distance and direction to an anomaly.
[0009] When logging measurements are used for well placement, detection or identification of anomalies can be critical. Such anomalies may include for example, a fault, a bypassed reservoir, a salt dome, or an adjacent bed or oil-water contact. It would be beneficial to determine both the distance and the direction of the anomaly from the drilling site.
[0010] Tri-axial induction logging devices, including wire-line and LWD devices are capable of providing directional resistivity measurements. However, no method has been proposed for utilizing these directional resistivity measurements to identify the direction to an anomaly.
[0011] Accordingly, a new solution is needed for determining the direction and distance from a tool to an anomaly. Furthermore, a real time solution having an increased depth of analysis is needed so that the measurements can be immediately useful to equipment operators.
SUMMARY OF THE INVENTION
[0012] In one aspect, an embodiment of the present invention is directed to a method for determining a direction to an anomaly in a formation near a wellbore. The method is implemented using a device including at least one transmitter and at least one receiver. The method includes transmitting electromagnetic signals from the transmitter through the formation near the wellbore and detecting responses at the receiver induced by the electromagnetic signals. The method additionally includes determining the direction and distance from the device to the anomaly based on the detected responses.
[0013] In a further aspect, a method for determining a direction and distance to an anomaly in a formation near a wellbore is provided. The method is accomplished using a device with at least one transmitter for transmitting electromagnetic signals and at least one receiver for detecting responses. The method includes calculating at least one of an apparent azimuth angle and an apparent dip angle based on the responses and monitoring the at least one calculated apparent angle over time. The method additionally includes determining the direction to the anomaly after the at least one monitored apparent angle deviates from a zero value.
[0014] In yet another aspect, an embodiment of the invention provides a method for determining a direction and distance to an anomaly in a formation near a wellbore. The method is implemented using a device including at least one transmitter for transmitting electromagnetic signals and a receiver for detecting responses. The method includes calculating at least one of an apparent azimuth angle and an apparent dip angle based on the responses and monitoring the at least one calculated apparent angle over time. The method additionally includes measuring the distance to the anomaly when the at least one monitored apparent angle reaches an asymptotic value.
[0015] In another embodiment, the invention provides a computer readable medium for storing computer executable instructions for performing a method for determining a direction to an anomaly in a system comprising a device with at least one transmitter for transmitting electromagnetic signals and a receiver for detecting responses. The method comprises calculating at least one of an apparent azimuth angle and an apparent dip angle based on the responses, monitoring the at least one calculated apparent angle over time, and determining the direction to the anomaly when the at least one monitored apparent angle reaches an asymptotic value.
[0016] In another embodiment, the invention provides a system for determining a direction to an anomaly in a formation near a wellbore. The system comprises at least one transmitter for transmitting electromagnetic signals through the formation near the wellbore, at least one receiver for detecting responses induced by the electromagnetic signal, and a computer readable medium storing instructions for determining the direction from the device to the anomaly based on the detected responses.
[0017] In another embodiment, the invention provides a computer readable medium for storing computer executable instructions for performing a method for determining a direction to an anomaly in a system comprising a device with at least one transmitter for transmitting electromagnetic signals and a receiver for detecting responses. The method comprises calculating at least one of an apparent azimuth angle and an apparent dip angle based on the responses, monitoring the at least one calculated apparent angle over time, and determining the direction to the anomaly after the at least one monitored angle deviates from a zero value.
[0018] In another embodiment, the invention provides a method for locating an anomaly in relation to a logging tool including at least one transmitter and at least one receiver in a formation near a wellbore. The method comprises measuring a voltage response over time at the at least one receiver, calculating an apparent conductivity over time based on the voltage response, and locating the anomaly based on variation of the apparent conductivity over time.
[0019] In another embodiment, the invention provides a method for locating an anomaly in relation to a logging tool including at least one transmitter and at least one receiver in a formation near a wellbore. The method comprises calculating an apparent conductivity over a selected time span based on the voltage response, determining a time at which the apparent conductivity deviates from a constant value, and ascertaining the anomaly in a region specified by the determined time.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] The present invention is described in detail below with reference to the attached drawing figures, wherein:
[0021] FIG. 1 is a block diagram showing a system in accordance with embodiment of the invention;
[0022] FIG. 2 is a flow chart illustrating a method in accordance with an embodiment of the invention;
[0023] FIG. 3 is a graph illustrating directional angles between tool coordinates and anomaly coordinates;
[0024] FIG. 4A is a graph showing a resistivity anomaly in a tool coordinate system;
[0025] FIG. 4B is a graph showing a resistivity anomaly in an anomaly coordinate system;
[0026] FIG. 5 is a graph illustrating tool rotation within a borehole;
[0027] FIG. 6 is a graph showing directional components;
[0028] FIG. 7 is a schematic showing apparent conductivity with a coaxial tool; and
[0029] FIG. 8 is a schematic showing apparent conductivity with a coplanar tool.
DETAILED DESCRIPTION OF THE INVENTION
[0030] Embodiments of the invention relate to a system and method for determining distance and direction to an anomaly in a formation within a wellbore. Both frequency domain excitation and time domain excitation have been used to excite electromagnetic fields for use in anomaly detection. In frequency domain excitation, a device transmits a continuous wave of a fixed or mixed frequency and measures responses at the same band of frequencies. In time domain excitation, a device transmits a square wave signal, triangular wave signal, pulsed signal or pseudo-random binary sequence as a source and measures the broadband earth response. Sudden changes in transmitter current cause signals to appear at a receiver caused by induction currents in the formation. The signals that appear at the receiver are called transient responses because the receiver signals start at a first value and then decay or increase with time to a constant level. The technique disclosed herein implements the time domain excitation technique.
[0031] As set forth below, embodiments of the invention propose a general method to determine a direction to a resistive or conductive anomaly using transient EM responses. As will be explained in detail, the direction to the anomaly is specified by a dip angle and an azimuth angle. Embodiments of the invention propose to define an apparent dip (θ app (t)) and an apparent azimuth (φ app (t)) by combinations of tri-axial transient measurements. An apparent direction ({θ app (t), θ app (t)}) approaches a true direction ({θ, φ}) as a time (t) increases. The θ app (t) and φ app (t) both initially read zero when an apparent conductivity σ coaxial (t) and σ coplanar (t) from coaxial and coplanar measurements both read the conductivity around the tool. The apparent conductivity will be further explained below and can also be used to determine the location of an anomaly in a wellbore.
[0032] FIG. 1 illustrates a system that may be used to implement the embodiments of the method of the invention. A surface computing unit 10 may be connected with an electromagnetic measurement tool 2 disposed in a wellbore 4 and supported by a cable 12 . The cable 12 may be constructed of any known type of cable for transmitting electrical signals between the tool 2 and the surface computing unit 10 . One or more transmitters 16 and one are more receivers 18 may be provided for transmitting and receiving signals. A data acquisition unit 14 may be provided to transmit data to and from the transmitters 16 and receivers 18 to the surface computing unit 10 .
[0033] Each transmitter 16 and each receiver 18 may be tri-axial and thereby contain components for sending and receiving signals along each of three axes. Accordingly, each transmitter module may contain at least one single or multi-axis antenna and may be a 3-orthogonal component transmitter. Each receiver may include at least one single or multi-axis electromagnetic receiving component and may be a 3-orthogonal component receiver.
[0034] The data acquisition unit 14 may include a controller for controlling the operation of the tool 2 . The data acquisition unit 14 preferably collects data from each transmitter 16 and receiver 18 and provides the data to the surface computing unit 10 .
[0035] The surface computing unit 10 may include computer components including a processing unit 30 , an operator interface 32 , and a tool interface 34 . The surface computing unit 10 may also include a memory 40 including relevant coordinate system transformation data and assumptions 42 , a direction calculation module 44 , an apparent direction calculation module 46 , and a distance calculation module 48 . The surface computing unit 10 may further include a bus 50 that couples various system components including the system memory 40 to the processing unit 30 . The computing system environment 10 is only one example of a suitable computing environment and is not intended to suggest any limitation as to the scope of use or functionality of the invention. Furthermore, although the computing system 10 is described as a computing unit located on a surface, it may optionally be located below the surface, incorporated in the tool, positioned at a remote location, or positioned at any other convenient location.
[0036] The memory 40 preferably stores the modules 44 , 46 , and 48 , which may be described as program modules containing computer-executable instructions, executed by the surface computing unit 10 . The program module 44 contains the computer executable instruction necessary to calculate a direction to an anomaly within a wellbore. The program module 46 includes the computer executable instructions necessary to calculate an apparent direction as will be further explained below. The program module 48 contains the computer executable instructions necessary to calculate a distance to an anomaly. The stored data 46 includes data pertaining to the tool coordinate system and the anomaly coordinate system and other data required for use by the program modules 44 , 46 , and 48 . These program modules 44 , 46 , and 48 , as well as the stored data 42 , will be further described below in conjunction with embodiments of the method of the invention.
[0037] Generally, program modules include routines, programs, objects, components, data structures, etc. 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. The invention may also be practiced in distributed computing environments where tasks are performed by remote processing devices that are linked through a communications network. In a distributed computing environment, program modules may be located in both local and remote computer storage media including memory storage devices.
[0038] Although the computing system 10 is shown as having a generalized memory 40 , the computing system 10 would typically includes a variety of computer readable media. By way of example, and not limitation, computer readable media may comprise computer storage media and communication media. The computing system memory 40 may include computer storage media in the form of volatile and/or nonvolatile memory such as a read only memory (ROM) and random access memory (RAM). A basic input/output system (BIOS), containing the basic routines that help to transfer information between elements within computer 10 , such as during start-up, is typically stored in ROM. The RAM typically contains data and/or program modules that are immediately accessible to and/or presently being operated on by processing unit 30 . By way of example, and not limitation, the computing system 10 includes an operating system, application programs, other program modules, and program data.
[0039] The components shown in the memory 40 may also be included in other removable/nonremovable, volatile/nonvolatile computer storage media. For example only, a hard disk drive may read from or write to nonremovable, nonvolatile magnetic media, a magnetic disk drive may read from or write to a removable, non-volatile magnetic disk, and an optical disk drive may read from or write to a removable, nonvolatile optical disk such as a CD ROM or other optical media. Other removable/non-removable, volatile/non-volatile computer storage media that can be used in the exemplary operating environment include, but are not limited to, magnetic tape cassettes, flash memory cards, digital versatile disks, digital video tape, solid state RAM, solid state ROM, and the like. The drives and their associated computer storage media discussed above and illustrated in FIG. 1 , provide storage of computer readable instructions, data structures, program modules and other data for the computing system 10 .
[0040] A user may enter commands and information into the computing system 10 through input devices such as a keyboard and pointing device, commonly referred to as a mouse, trackball or touch pad. Input devices may include a microphone, joystick, satellite dish, scanner, or the like. These and other input devices are often connected to the processing unit 30 through the operator interface 32 that is coupled to the system bus 50 , but may be connected by other interface and bus structures, such as a parallel port or a universal serial bus (USB). A monitor or other type of display device may be connected to the system bus 50 via an interface, such as a video interface. In addition to the monitor, computers may also include other peripheral output devices such as speakers and printer, which may be connected through an output peripheral interface.
[0041] Although many other internal components of the computing system 10 are not shown, those of ordinary skill in the art will appreciate that such components and the interconnection are well known. Accordingly, additional details concerning the internal construction of the computer 10 need not be disclosed in connection with the present invention.
[0042] FIG. 2 is a flow chart illustrating the procedures involved in a method of the invention. Generally, in procedure A, the transmitters 16 transmit electromagnetic signals. In procedure B, the receivers 18 receive transient responses. In procedure C, the system processes the transient responses to determine a distance and direction to the anomaly.
[0043] FIGS. 3-6 illustrate the technique for implementing procedure C for determining distance and direction to the anomaly.
[0000] Tri-Axial Transient EM Responses
[0044] FIG. 3 illustrates directional angles between tool coordinates and anomaly coordinates. A transmitter coil T is located at an origin that serves as the origin for each coordinate system. A receiver R is placed at a distance L from the transmitter. An earth coordinate system, includes a Z-axis in a vertical direction and an X-axis and a Y-axis in the East and the North directions, respectively. The deviated borehole is specified in the earth coordinates by a deviation angle θ b and its azimuth angle φ b . A resistivity anomaly A is located at a distance D from the transmitter in the direction specified by a dip angle (θ a ) and its azimuth (φ a ).
[0045] In order to practice embodiments of the method, FIG. 4A shows the definition of a tool/borehole coordinate system having x, y, and z axes. The z-axis defines the direction from the transmitter T to the receiver R. The tool coordinates in FIG. 4A are specified by rotating the earth coordinates (X, Y, Z) in FIG. 3 by the azimuth angle (φ b ) around the Z-axis and then rotating by θ b around the y-axis to arrive at the tool coordinates (x, y, z). The direction of the anomaly is specified by the dip angle (θ) and the azimuth angle (φ) where:
cos ϑ = ( b ^ z · a ^ ) = cos θ a cos θ b + sin θ a sin θ b cos ( φ a - φ b ) ( 1 ) tan ϕ = sin θ b sin ( φ a - φ b ) cos θ a sin θ b cos ( φ a - φ b ) - sin θ a cos θ b ( 2 )
[0046] Similarly, FIG. 4B shows the definition of an anomaly coordinate system having a, b, and c axes. The c-axis defines the direction from the transmitter T to the center of the anomaly A. The anomaly coordinates in FIG. 4B are specified by rotating the earth coordinates (X, Y, Z) in FIG. 3 by the azimuth angle (φ a ) around the Z-axis and subsequently rotating by θ a around the b-axis to arrive at the anomaly coordinates (a, b, c). In this coordinate system, the direction of the borehole is specified in a reverse order by the azimuth angle (φ) and the dip angle (θ).
[0000] Transient Responses in Two Coordinate Systems
[0047] The method is additionally based on the relationship between the transient responses in two coordinate systems. The magnetic field transient responses at the receivers [R x , R y , R z ] which are oriented in the [x, y, z] axis direction of the tool coordinates, respectively, are noted as
[ V xx V xy V xz V yx V yy V yz V zx V zy V zz ] = [ R x R y R z ] [ M x M y M z ] ( 3 )
from a magnetic dipole source in each axis direction, [M x , M y , M z ].
[0049] When the resistivity anomaly is distant from the tool, the formation near the tool is seen as a homogeneous formation. For simplicity, the method may assume that the formation is isotropic. Only three non-zero transient responses exist in a homogeneous isotropic formation. These include the coaxial response and two coplanar responses. Coaxial response V zz (t) is the response when both the transmitter and the receiver are oriented in the common tool axis direction. Coplanar responses, V xx (t) and V yy (t), are the responses when both the transmitter T and the receiver R are aligned parallel to each other but their orientation is perpendicular to the tool axis. All of the cross-component responses are identically zero in a homogeneous isotropic formation. Cross-component responses are either from a longitudinally oriented receiver with a transverse transmitter, or vise versa. Another cross-component response is also zero between a mutually orthogonal transverse receiver and transverse transmitter.
[0050] The effect of the resistivity anomaly is seen in the transient responses as time increases. In addition to the coaxial and the coplanar responses, the cross-component responses V ij (t) (i≠j, j=x, y, z) become non-zero.
[0051] The magnetic field transient responses may also be examined in the anomaly coordinate system. The magnetic field transient responses at the receivers [R a , R b , R c ] that are oriented in the [a, b, c] axis direction of the anomaly coordinates, respectively, may be noted as
[ V aa V ab V a c V ba V bb V bc V ca V cb V cc ] = [ R a R b R c ] [ M a M b M c ] ( 4 )
from a magnetic dipole source in each axis direction, [M a , M b , M c ].
[0053] When the anomaly is large and distant compared to the transmitter-receiver spacing, the effect of spacing can be ignored and the transient responses can be approximated with those of the receivers near the transmitter. Then, the method assumes that axial symmetry exists with respect to the c-axis that is the direction from the transmitter to the center of the anomaly. In such an axially symmetric configuration, the cross-component responses in the anomaly coordinates are identically zero in time-domain measurements.
[ V aa V ab V a c V ba V bb V bc V ca V cb V cc ] = [ V aa 0 0 0 V aa 0 0 0 V cc ] ( 5 )
[0054] The magnetic field transient responses in the tool coordinates are related to those in the anomaly coordinates by a simple coordinate transformation P(θ, φ) specified by the dip angle (θ) and azimuth angle (φ).
[ V xx V xy V xz V yx V yy V yz V zx V zy V zz ] = P ( ϑ , ϕ ) tr [ V aa V ab V a c V ba V bb V bc V ca V cb V cc ] P ( ϑ , ϕ ) ( 6 ) P ( ϑ , ϕ ) = [ cos ϑ cos ϕ cos ϑ sin ϕ - sin ϑ - sin ϕ cos ϕ 0 sin ϑ cos ϕ sin ϑ sin ϕ cos ϑ ] ( 7 )
Determination of Target Direction
[0055] The assumptions set forth above contribute to determination of target direction, which is defined as the direction of the anomaly from the origin. When axial symmetry in the anomaly coordinates is assumed, the transient response measurements in the tool coordinates are constrained and the two directional angles may be determined by combinations of tri-axial responses.
[ V xx V xy V xz V yx V yy V yz V zx V zy V zz ] = P ( ϑ , ϕ ) tr [ V aa 0 0 0 V aa 0 0 0 V cc ] P ( ϑ , ϕ ) ( 8 )
[0056] In terms of each tri-axial response
V xx =( V aa cos 2 θ+V cc sin 2 θ)cos 2 φ+V aa sin 2 φ
V yy =( V aa cos 2 θ+V cc sin 2 θ)sin 2 φ+V aa cos 2 φ
V zz =V aa sin 2 θ+V cc cos 2 φ (9)
V xy =V yx =−( V aa −V cc )sin 2 θ cos φ sin φ
V zx =V xz =−( V aa −V cc )cos θ sin θ cos φ
V yz = Vzy =−( V aa −V cc )cos θ sin θ sin φ (10)
[0057] The following relations can be noted:
V xx +V yy +V zz =2 V aa +V cc
V xx −V yy =( V cc −V aa )sin 2 θ(cos 2 θ−sin 2 φ)
V yy −V zz =−( V cc −V aa )(cos 2 θ−sin 2 θ sin 2 φ)
V zz −V xx =( V cc −V aa )(cos 2 θ−sin 2 θ cos 2 φ) (11)
[0058] Several distinct cases can be noted. In the first of these cases, when none of the cross-components is zero, V xy ≠0 nor V yz ≠0 nor V zx ≠0, then the azimuth angle φ is not zero nor π/2 (90°), and can be determined by,
ϕ = 1 2 tan - 1 V xy + V yx V xx - V yy ϕ = tan - 1 V yz V xz = tan - 1 V zy V zx ( 12 )
[0059] By noting the relation,
V xy V xz = tan ϑ sin ϕ and V xy V yz = tan ϑ cos ϕ ( 13 )
the dip (deviation) angle θ is determined by,
tan ϑ = ( V xy V xz ) 2 + ( V xy V yz ) 2 ( 14 )
[0061] In the second case, when V xy =0 and V yz =0, then θ=0 or φ=0 or π (180°) or φ=±π/2 (90°) and θ=±π/2 (90°), as the coaxial and the coplanar responses should differ from each other (V aa ≠V cc ).
[0062] If φ=0, then the dip angle θ is determined by,
ϑ = - 1 2 tan - 1 V xz + V zx V xx - V zz ( 15 )
[0063] If φ=π (180°), then the dip angle θ is determined by,
ϑ = + 1 2 tan - 1 V xz + V zx V xx - V zz ( 16 )
[0064] Also, with regard to the second case, If θ= 0 , then V xx =V yy and V zx =0. If φ=±π/2 (90°) and θ=±π/2 (90°), then V zz =V xx and V zx =0. These instances are further discussed below with relation to the fifth case.
[0065] In the third case, when V xy =0 and V xz =0, then φ=±π/2 (90°) or θ=0 or φ=0 and θ=±π/2 (90°).
[0066] If φ=π/2, then the dip angle θ is determined by,
ϑ = - 1 2 tan - 1 V yz + V zy V yy - V zz ( 17 )
[0067] If φ=−π/2, then the dip angle θ is determined by,
ϑ = + 1 2 tan - 1 V yz + V zy V yy - V zz ( 18 )
[0068] Also with regard to the third case, If σ=0, then V xx =V yy and V yz =0. If φ=0 and θ=±π/2 (90°), V yy =V zz and V yz =0. These situations are further discussed below with relation to the fifth case.
[0069] In the fourth case, V xz =0 and V yz =0, then θ=0 or π(180°) or ±π/2 (90°).
[0070] If θ=±π/2, then the azimuth angle φ is determined by,
ϕ = - 1 2 tan - 1 V xy + V yx V xx - V yy ( 19 )
[0071] Also with regard to the fourth case, if θ=0 or π(180°), then V xx =V yy and V yz =0. This situation is also shown below with relation to the fifth case.
[0072] In the fifth case, all cross components vanish, V xz =V yz =V xy =0, then θ=0, or θ=±π/2 (90°) and φ=0 or ±π/2 (90°).
[0073] If V xx =V yy then θ=0 or π(180°).
[0074] If V yy =V zz then θ=±π/2 (90°) and φ=0.
[0075] If V zz =V xx then θ=±π/2 (90°) and φ=±π/2 (90°).
[0000] Tool Rotation Around the Tool/Borehole Axis
[0076] In the above analysis, all the transient responses V ij (t) (i, j=x, y, z) are specified by the x-, y-, and z-axis directions of the tool coordinates. However, the tool rotates inside the borehole and the azimuth orientation of the transmitter and the receiver no longer coincides with the x- or y-axis direction as shown in FIG. 5 . If the measured responses are {tilde over (V)} ĩ{tilde over (j)} (ĩ, {tilde over (j)}={tilde over (x)}, {tilde over (y)}, z) where {tilde over (x)} and {tilde over (y)} axis are the direction of antennas fixed to the rotating tool, and ψ is the tool's rotation angle, then
[ V x ~ x ~ V x ~ y ~ V x ~ z V y ~ x ~ V y ~ y ~ V y ~ z V z x ~ V z y ~ V zz ] = R ( ψ ) tr [ V xx V xy V xz V yx V yy V yz V zx V zy V zz ] R ( ψ ) ( 20 ) R ( ψ ) = [ cos ψ - sin ψ 0 sin ψ cos ψ 0 0 0 1 ] ( 21 )
[0077] Then,
V {tilde over (x)}{tilde over (x)} =( V aa cos 2 θ+V cc sin 2 θ)cos 2 (φ−ψ)+ V aa sin 2 (φ−ψ)
V {tilde over (y)}{tilde over (y)} =( V aa cos 2 θ+V cc sin 2 θ)sin 2 (φ−ψ)+ V aa cos 2 (φ−ψ)
V zz =V aa sin 2 θ+V cc cos 2 θ (22)
V {tilde over (x)}{tilde over (y)} =V {tilde over (y)}{tilde over (x)} =−( V aa −V cc ) sin 2 θ cos(φ−ψ)sin(φ−ψ)
V z{tilde over (x)} =V {tilde over (x)}z =−( V aa −V cc )cos θ sin θ cos(φ−ψ)
V {tilde over (y)}z =V z{tilde over (y)} =−( V aa −V cc )cos θ sin θ sin(φ−ψ) (23)
[0078] The following relations apply:
V {tilde over (x)}{tilde over (x)} +V {tilde over (y)}{tilde over (y)} +V zz =2 V aa +V cc
V {tilde over (x)}{tilde over (x)} −V {tilde over (y)}{tilde over (y)} =( V cc −V aa )sin 2 θ{cos 2 (φ−ψ)−sin 2 (φ−ψ)}
V {tilde over (y)}{tilde over (y)} −V zz =−( V cc −V aa ){cos 2 θ−sin 2 θ sin 2 (φ−ψ)}
V zz −V {tilde over (x)}{tilde over (x)} =( V cc −V aa ){cos 2 θ−sin 2 θ cos 2 (φ−ψ)}
[0079] Consequently,
ϕ - ψ = 1 2 tan - 1 V x ~ y ~ + V y ~ x ~ V x ~ x ~ - V y ~ y ~ ϕ - ψ = tan - 1 V y ~ z V x ~ z = tan - 1 V z y ~ V z x ~ ( 25 )
[0080] The azimuth angle φ is measured from the tri-axial responses if the tool rotation angle ψ is known. To the contrary, the dip (deviation) angle θ is determined by
tan ϑ = ( V x ~ y ~ V x ~ z ) 2 + ( V x ~ y ~ V y ~ z ) 2 ( 26 )
without knowing the tool orientation ψ.
Apparent Dip Angle and Azimuth Angle and the Distance to the Anomaly
[0082] The dip and the azimuth angle described above indicate the direction of a resistivity anomaly determined by a combination of tri-axial transient responses at a time (t) when the angles have deviated from a zero value. When t is small or close to zero, the effect of such anomaly is not apparent in the transient responses as all the cross-component responses are vanishing. To identify the anomaly and estimate not only its direction but also the distance, it is useful to define the apparent azimuth angle φ app (t) by,
ϕ app ( t ) = 1 2 tan - 1 V xy ( t ) + V yx ( t ) V xx ( t ) - V yy ( t ) ϕ app ( t ) = tan - 1 V yz ( t ) V xz ( t ) = tan - 1 V zy ( t ) V zx ( t ) ( 27 )
and the effective dip angle θ app (t) by
tan ϑ app ( t ) = ( V xy ( t ) V xz ( t ) ) 2 + ( V xy ( t ) V yz ( t ) ) 2 ( 28 )
for the time interval when φ app (t)≠0 nor π/2 (90°). For simplicity, the case examined below is one in which none of the cross-component measurements is identically zero: V xy (t)≠0, V yz (t)≠0, and V zx (t)≠0.
[0083] For the time interval when φ app (t)=0, θ app (t) is defined by,
ϑ app ( t ) = - 1 2 tan - 1 V xz ( t ) + V zx ( t ) V xx ( t ) - V zz ( t ) ( 29 )
[0084] For the time interval when φ app (t)=π/2 (90°), θ app (t) is defined by,
ϑ app ( t ) = - 1 2 tan - 1 V yz ( t ) + V zy ( t ) V yy ( t ) - V zz ( t ) ( 30 )
[0085] When t is small and the transient responses do not see the effect of a resistivity anomaly at distance, the effective angles are identically zero, φ app (t)=θ app (t)=0. As t increases, when the transient responses see the effect of the anomaly, φ app (t) and θ app (t) begin to show the true azimuth and the true dip angles. The distance to the anomaly may be indicated at the time when φ app (t) and θ app (t) start deviating from the initial zero values. As shown below in a modeling example, the presence of an anomaly is detected much earlier in time in the effective angles than in the apparent conductivity (σ app (t)). Even if the resistivity of the anomaly may not be known until σ app (t) is affected by the anomaly, its presence and the direction can be measured by the apparent angles. With limitation in time measurement, the distant anomaly may not be seen in the change of σ app (t) but is visible in φ app (t) and θ app (t).
[0000] Modeling Example
[0086] A simplified modeling example exists when a resistivity anomaly is a massive salt dome, and the salt interface may be regarded as a plane interface. For further simplification, it can be assumed that the azimuth of the salt face is known. Accordingly, the remaining unknowns are the distance D to the salt face from the tool, the isotropic or anisotropic formation resistivity, and the approach angle (or dip angle) θ as shown in FIG. 6 .
[0087] Table 1 and Table 2 below show the voltage from the coaxial V zz (t), coplanar V xx (t), and the cross-component V zx (t) measurements for L=1 m, for θ=30°, and at salt distance D=10 m and D=100 m respectively. The apparent dip θ app (t) is defined by,
θ app ( t ) = - 1 2 tan - 1 V zx ( t ) + V xz ( t ) V zz ( t ) - V xx ( t ) . ( 31 )
[0088] Table 3 below shows the apparent dip (θ app (t)) for the L=1 m tool assembly when the salt face is D=10 m away and at the approach angle of θ=30°.
[0089] In addition, the apparent conductivity (θ app (t)) from both the coaxial (V zz (t)) and the coplanar (V xx (t)) responses is shown in Table 4, wherein the approach angle (θ) and salt face distance (D) are the same as in Table 3.
[0090] Also plotted is the ratio, σ app-coplanar (t)/σ app-coaxial (t), that is available without cross-component V zx (t) measurements as shown in Table 5, wherein the approach angle (θ) and salt face distance (D) are the same as in FIG. 3 .
[0091] Note that the direction to the salt face is immediately identified in the apparent dip θ app (t) plot of Table 3 as early as 10 −4 second when the presence of the resistivity anomaly is barely detected in the apparent conductivity (θ app (t)) plot of Table 4. It takes almost 10 −3 second for the apparent conductivity to approach an asymptotic σ app (later t) value and for the apparent conductivity ratio to read θ=30°.
[0092] Table 6 below shows the apparent dip θ app (t) for the L=Im tool assembly when the salt face is D=10 m away, but at different angles between the tool axis and the target. The approach angle (θ) may be identified at any angle.
[0093] Tables 7, 8, and 9 below compare the apparent dip θ app (t) for different salt face distances (D) and different angles between the tool axis and the target.
[0094] The distance to the salt face can be also determined by the transition time at which θ app (t) takes an asymptotic value. Even if the salt face distance (D) is 100 m, it can be identified and its direction can be measured by the apparent dip θ app (t).
[0095] In summary, the method considers the coordinate transformation of transient EM responses between tool-fixed coordinates and anomaly-fixed coordinates. When the anomaly is large and far away compared to the transmitter-receiver spacing, one may ignore the effect of spacing and approximate the transient EM responses with those of the receivers near the transmitter. Then, one may assume axial symmetry exists with respect to the c-axis that defines the direction from the transmitter to the anomaly. In such an axially symmetric configuration, the cross-component responses in the anomaly-fixed coordinates are identically zero. With this assumption, a general method is provided for determining the direction to the resistivity anomaly using tri-axial transient EM responses.
[0096] The method defines the apparent dip θ app (t) and the apparent azimuth φ app (t) by combinations of tri-axial transient measurements. The apparent direction {θ app (t), φ app (t)} reads the true direction {θ, φ} at later time. The θ app (t) and φ app (t) both read zero when t is small and the effect of the anomaly is not sensed in the transient responses or the apparent conductivity. The conductivities (σ coaxial (t) and σ coplanar (t)) from the coaxial and coplanar measurements both indicate the conductivity of the near formation around the tool.
[0097] Deviation of the apparent direction ({θ app (t), φ app (t)}) from zero identifies the anomaly. The distance to the anomaly is measured by the time when the apparent direction ({θ app (t), φ app (t)}) approaches the true direction ({θ, φ}). The distance can be also measured from the change in the apparent conductivity. However, the anomaly is identified and measured much earlier in time in the apparent direction than in the apparent conductivity.
[0000] Apparent Conductivity
[0098] As set forth above, apparent conductivity can be used as an alternative technique to apparent angles in order to determine the location of an anomaly in a wellbore. The time-dependent apparent conductivity can be defined at each point of a time series at each logging depth. The apparent conductivity at a logging depth z is defined as the conductivity of a homogeneous formation that would generate the same tool response measured at the selected position.
[0099] In transient EM logging, transient data are collected at a logging depth or tool location z as a time series of induced voltages in a receiver loop. Accordingly, time dependent apparent conductivity (σ(z; t)) may be defined at each point of the time series at each logging depth, for a proper range of time intervals depending on the formation conductivity and the tool specifications.
[0000] Apparent Conductivity for a Coaxial Tool
[0100] The induced voltage of a coaxial tool with transmitter-receiver spacing L in the homogeneous formation of conductivity (σ) is given by,
V zZ ( t ) = C ( μ o σ ) 3 2 8 t 5 2 ⅇ - u 2 where u 2 = μ o σ 4 L 2 t and C is a constant . ( 32 )
[0101] FIG. 7 illustrates a coaxial tool in which both a transmitter coil (T) and a receiver coil (R) are wound around the common tool axis. The symbols σ 1 and σ 2 may represent the conductivities of two formation layers. This tool is used to illustrate the voltage response for different values of t and L in Tables 10-12 below, where σ 1 =σ 2 .
[0102] Table 10 shows the voltage response of the coaxial tool with L=0.1 m in a homogeneous formation for various formation resistivities (R) from 1000 ohm-m to 0.1 ohm-m. The voltage is positive at all times t for t>0. The slope of the voltage is nearly constant
∂ ln V zZ ( t ) ∂ ln t ≈ - 5 2
in the time interval between 10 −8 second and 1 second (and later) for any formation resistivity larger than 10 ohm-m. The slope changes sign at an earlier time around 10 −6 second when the resistivity is low as 0.1 ohm-m.
[0103] Table 11 shows the voltage response as a function of formation resistivity at different times (t) for the same coaxial tool spacing (L=01 m). For the resistivity range from 0.1 ohm-m to 100 ohm-m, the voltage response is single valued as a function of formation resistivity for the measurement time (t) later than 10 −6 second. At smaller times (t), for instance at 10 −7 second, the voltage is no longer single valued. The same voltage response is realized at two different formation resistivity values.
[0104] Table 12 shows the voltage response as a function of formation resistivity for a larger transmitter-receiver spacing of L=10 m on a coaxial tool. The time interval when the voltage response is single valued is shifted toward larger times (t). The voltage response is single valued for resistivity from 0.1 ohm-m to 100 ohm-m, for the measurement time (t) later than 10 −4 second. At smaller values of t, for instance at t=10 −5 second, the voltage is no longer single valued. The apparent conductivity from a single measurement (coaxial, single spacing) alone is not well defined.
[0105] For relatively compact transmitter-receiver spacing (L=1 m to 10 m), and for the time measurement interval where t is greater than 10 −6 second, the transient EM voltage response is mostly single valued as a function of formation resistivity between 0.1-ohm-m and 100 ohm-m (and higher). This enables definition of the time-changing apparent conductivity from the voltage response (V zZ (t)) at each time of measurement as:
C ( μ o σ app ( t ) ) 3 2 8 t 5 2 ⅇ - u app ( t ) 2 = V zZ ( t ) ( 33 )
where
u app ( t ) 2 = μ o σ app ( t ) 4 L 2 t
and V zZ (t) on the right hand side is the measured voltage response of the coaxial tool. From a single type of measurement (coaxial, single spacing), the greater the spacing L, the larger the measurement time (t) should be to apply the apparent conductivity concept. The σ app (t) should be constant and equal to the formation conductivity in a homogeneous formation: σ app (t)=σ. The deviation from a constant (σ) at time (t) suggests a conductivity anomaly in the region specified by time (t).
Apparent Conductivity for a Coplanar Tool
[0106] The induced voltage of the coplanar tool with transmitter-receiver spacing L in the homogeneous formation of conductivity (σ) is given by,
V xX ( t ) = C ( μ 0 σ app ( t ) ) 3 2 8 t 5 2 ( 1 - u 2 ) ⅇ - u 2 ( 34 )
where
u 2 = μ 0 σ app ( t ) 4 t L 2
and C is a constant. At small values of t, the coplanar voltage changes polarity depending on the spacing L and the formation conductivity.
[0107] FIG. 8 illustrates a coplanar tool in which the transmitter (T) and the receiver (R) are parallel to each other and oriented perpendicularly to the tool axis. The symbols σ 1 and σ 2 may represent the conductivities of two formation layers. This tool is used to illustrate the voltage response for different values of t and L in Tables 13-14 below, where σ 1 =σ 2 .
[0108] Table 13 shows the voltage response of a coplanar tool with a length L=01 m as a function of formation resistivity at different times (t). For the resistivity range from 0.1 ohm-m to 100 ohm-m, the voltage response is single valued as a function of formation resistivity for values of t larger than 10 −6 second. At smaller values of t, for instance at t=10 −7 second, the voltage changes polarity and is no longer single valued.
[0109] Table 14 shows the voltage response as a function of formation resistivity at different times (t) for a longer coplanar tool with a length L=05 m. The time interval when the voltage response is single valued is shifted towards larger values of t.
[0110] Similarly to the coaxial tool response, the time-changing apparent conductivity is defined from the coplanar tool response V xX (t) at each time of measurement as,
C ( μ o σ app ( t ) ) 3 2 8 t 5 2 ( 1 - u app ( t ) 2 ) ⅇ - u app ( t ) 2 = V xX ( t ) ( 35 )
where
u app ( t ) 2 = μ o σ app ( t ) 4 L 2 t
and V xX (t) on the right hand side is the measured voltage response of the coplanar tool. The longer the spacing, the larger the value t should be to apply the apparent conductivity concept from a single type of measurement (coplanar, single spacing). The σ app (t) should be constant and equal to the formation conductivity in a homogeneous formation: σ app (t)=σ.
Apparent Conductivity for a Pair of Coaxial Tools
[0111] When there are two coaxial receivers, the ratio between the pair of voltage measurements is given by,
V zZ ( L 1 ; t ) V zZ ( L 2 ; t ) = ⅇ - μ o σ 4 t ( L 1 2 - L 2 2 ) ( 36 )
where L 1 and L 2 are transmitter-receiver spacing of two coaxial tools.
[0112] Conversely, the time-changing apparent conductivity is defined for a pair of coaxial tools by,
σ app ( t ) = - ln ( V zZ ( L 1 ; t ) V zZ ( L 2 ; t ) ) ( L 1 2 - L 2 2 ) 4 t μ o ( 37 )
at each time of measurement. The σ app (t) should be constant and equal to the formation conductivity in a homogeneous formation: σ app (t)=σ.
[0113] The apparent conductivity is similarly defined for a pair of coplanar tools or for a pair of coaxial and coplanar tools. The σ app (t) should be constant and equal to the formation conductivity in a homogeneous formation: σ app (t)=σ: The deviation from a constant (σ) at time (t) suggests a conductivity anomaly in the region specified by time (t).
[0000] Analysis of Coaxial Transient Response in Two-Layer Models
[0114] To illustrate usefulness of the concept of apparent conductivity, the transient response of a tool in a two-layer earth model, as in FIG. 7 for example, can be examined. A coaxial tool with a transmitter-receiver spacing L may be placed in a horizontal well. Apparent conductivity (σ app (t)) reveals three parameters including: (1) the conductivity (σ 1 , 0.1 S/m) of a first layer in which the tool is placed; (2) the conductivity (σ 2 =1 S/m) of an adjacent bed; and (3) the distance of the tool (horizontal borehole) to the layer boundary, d=1, 5, 10, 25, and 50 m.
[0115] Under a more general circumstance, the relative direction of a borehole and tool to the bed interface is not known. In the case of horizontal well logging, it's trivial to infer that the tool is parallel to the interface as the response does not change when the tool moves.
[0116] The voltage response of the L=01 m transmitter-receiver offset coaxial tool at different distances is shown in Table 15. Information can be derived from these responses using apparent conductivity as further explained with regard to Table 16. Table 16 shows the voltage data of Table 15 plotted in terms of apparent conductivity. The apparent conductivity plot shows conductivity at small t, conductivity at large t, and the transition time that moves as the distance (d) changes
[0117] As will be further explained below, in a two-layer resistivity profile, the apparent conductivity as t approaches zero can identify the layer conductivity around the tool, while the apparent conductivity as t approaches infinity can be used to determine the conductivity of the adjacent layer at a distance. The distance to a bed boundary from the tool can also be measured from the transition time observed in the apparent conductivity plot. The apparent conductivity plot for both time and tool location may be used as an image presentation of the transient data. Similarly, Table 17 illustrates the apparent conductivity in a two-layer model where σ 1 =1 S/m (R 1 =1 ohm-m) and σ 2 =0.1 S/m (R 2 =1 ohm-m).
[0000] Conductivity at Small Values of t
[0118] At small values of t, the tool reads the apparent conductivity of the first layer around the tool. At large values of t, the tool reads 0.4 S/m for a two-layer model where σ 1 =0.1 S/m (R 1 =10 ohm-m) and σ 2 =1 S/m (R 2 =1 ohm-m), which is an average between the conductivities of the two layers. The change of distance (d) is reflected in the transition time.
[0119] Conductivity at small values of t is the conductivity of the local layer where the tool is located. At small values of t, the signal reaches the receiver directly from the transmitter without interfering with the bed boundary. Namely, the signal is affected only by the conductivity around the tool. Conversely, the layer conductivity can be measured easily by examining the apparent conductivity at small values of t.
[0000] Conductivity at Large Values of t
[0120] Conductivity at large values of t is some average of conductivities of both layers. At large values of t, nearly half of the signals come from the formation below the tool and the remaining signals come from above, if the time for the signal to travel the distance between the tool and the bed boundary is small.
[0121] Table 18 compares the θ app (t) plot of Tables 16 and 17 for L=1 m and d=1 m where the resistivity ratio R 1 /R 2 is 10:1 in Table 16 and 1:10 in Table 17. Though not shown, the conductivity at large values of t has a slight dependence on d. When the dependence is ignored, the conductivity at large values of t is determined solely by the conductivities of the two layers and is not affected by the location of the tool in layer 1 or layer 2.
[0122] Table 19 compares the σ app (t) plots for d=1 m but with different spacings L. The σ app (t) reaches the nearly constant conductivity at large values of t as L increases. However, the conductivity at large values of t is almost independent of the spacing L for the range of d and the conductivities considered.
[0123] Table 20 compares the σ app (t) plots for d=1 m and L=1 m but for different resistivity ratios. The apparent conductivity at large t is proportional to σ 1 for the same ratio (σ 1 /σ 2 ). For instance:
σ app ( t→∞; R 1 /R 2 =10 ohm-m, R 1 =10 ohm-m)=10*σ app ( t→∞; R 1 /R 2 =10 ohm-m, R 1 =100 ohm-m) (38)
[0124] Table 21 shows examples of the σ app (t) plots for d=1 m and L=1 m but for different resistivity ratios of the target layer 2 while the local conductivity (σ 1 ) is fixed at 1 S/m (R 1 =1 ohm-m). The apparent conductivity at large values of t is determined by the target layer 2 conductivity, as shown in Table 22 when σ 1 is fixed 1 S/m.
[0125] Numerically, the late time conductivity may be approximated by the square root average of two-layer conductivities as:
σ app ( t → ∞ ; σ 1 , σ 2 ) = σ 1 + σ 2 2 ( 39 )
[0126] To summarize, the conductivity at large values of t (as t approaches infinity) can be used to estimate the conductivity (σ 2 ) of the adjacent layer when the local conductivity (σ 1 ) near the tool is known, for instance from the conductivity as t approaches 0 as illustrated in Table 23.
[0000] Estimation of d, the Distance to the Adjacent Bed
[0127] The transition time at which the apparent conductivity (σ app (t)) starts deviating from the local conductivity (σ 1 ) towards the conductivity at large values of t depends on d and L, as shown in Table 24.
[0128] For convenience, the transition time (t c ) can be defined as the time at which the σ app (t c ) takes the cutoff conductivity (σ c ). In this case, the cutoff conductivity is represented by the arithmetic average between the conductivity as t approaches zero and the conductivity as t approaches infinity. The transition time (t c ) is dictated by the ray path:
( L 2 ) 2 + d 2 , ( 40 )
that is the shortest distance for the EM signal traveling from the transmitter to the bed boundary, to the receiver, independently of the resistivity of the two layers. Conversely, the distance (d) can be estimated from the transition time (t c ), as shown in Table 25.
Other Uses of Apparent Conductivity
[0129] Similarly to conventional induction tools, the apparent conductivity (σ app (z)) is useful for analysis of the error in transient signal processing. The effect of the noise in transient response data may be examined as the error in the conductivity determination.
[0130] A plot of the apparent conductivity (σ app (z; t)) for different distances (d) in both the z and t coordinates may serve as an image presentation of the transient data as shown in Table 26 for a L=01 m tool. The z coordinate references the tool depth along the borehole. The σ app (z; t) plot shows the approaching bed boundary as the tool moves along the borehole.
[0131] The apparent conductivity should be constant and equal to the formation conductivity in a homogeneous formation. The deviation from a constant conductivity value at time (t) suggests the presence of a conductivity anomaly in the region specified by time (t).
[0132] In summary, the method allows real-time location of an anomaly in a borehole. The location of the anomaly is defined by its distance and direction from an origin. As demonstrated, the distance and direction can be determined based on magnetic field transient responses.
[0133] The present invention has been described in relation to particular embodiments, which are intended in all respects to be illustrative rather than restrictive. Alternative embodiments will become apparent to those skilled in the art to which the present invention pertains without departing from its scope.
[0134] From the foregoing, it will be seen that this invention is one well adapted to attain all the ends and objects set forth above, together with other advantages, which are obvious and inherent to the system and method. It will be understood that certain features and sub-combinations are of utility and may be employed without reference to other features and sub-combinations. This is contemplated and within the scope of the claims. | A method and a system are provided for allowing determination of a direction and distance from a tool to anomaly in a formation. The apparatus for performing the method includes at least one transmitter and at least one receiver. An embodiment of the method includes transmitting electromagnetic signals from the at least one transmitter through the formation near the wellbore and detecting responses at the at least one receiver induced by the electromagnetic signals. The method may further include determining the direction from the device to the anomaly based on the detected responses. The method may also include calculating at least one of an apparent azimuth angle and an apparent dip angle based on the responses, monitoring the at least one calculated apparent angle over time, and determining the direction to the anomaly after the at least one monitored apparent angle deviates from a zero value. | 6 |
CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. Nonprovisional application Ser. No. 14/221,975, filed Mar. 21, 2014, which is a continuation of U.S. Nonprovisional application Ser. No. 13/719,104, now U.S. Pat. No. 8,719,409, filed Dec. 18, 2012, which is a continuation of U.S. Nonprovisional application Ser. No. 12/830,188, now U.S. Pat. No. 8,359,387, filed Jul. 2, 2010, which is a continuation of U.S. Nonprovisional application Ser. No. 11/282,359, now U.S. Pat. No. 7,769,863 filed Nov. 17, 2005, which claims the benefit of U.S. Provisional Application No. 60/629,817, filed Nov. 19, 2004, the entire contents of which are incorporated herein by reference in their entirety for all purposes.
BACKGROUND
[0002] This disclosure relates in general to networking and, more specifically, but not by way of limitation, to networking over controlled long delay links.
[0003] Network access via satellite link has many speed limitations imposed by the long time delay of the link. Since the bulk of the Internet is composed of landline and short wireless links, communication delay has traditionally been associated with either slow or congested links. This bias has translated into standard protocols that create typical delays for satellite users that are much longer than just the sum of the typical landline delay plus the inherent satellite transmission delay.
[0004] Since one of the main uses for the Internet is web browsing, much effort has been done to speed up the loading of web pages over long delay links. For example, “ A Smart Internet Caching System ” Dias, et al., Internet Society INET 1996, is directed toward the acceleration of web browsing by the use of an intelligent agent at a distant (in terms of transmission time) gateway. One function of this agent is to observe base pages as they come from web servers and pre-fetch any in-line files (for example, images) that are referred to in the base page. These files are then pushed across the long delay link to be cached for immediate access by the user upon request. Although this method can be employed on satellite links, it has serious limitations because of the overhead involved and the possibility of pushing unneeded information over the long delay link. For example, if a user is loading the home page for a shopping server, the home page may be customized to that user. In this case, the link resources would be wasted loading generic in-line elements that do not apply to the current user. As well, locally running web applications such as Java are not well served by a pre-fetching technique.
BRIEF SUMMARY
[0005] In one embodiment, the present disclosure provides a communication system for providing network access over a shared communication link. The communication system includes a user access point, a network access point and a communications link. The user access point is coupled to one or more user terminals that access a remote network. The network access point is coupled to the remote network. The communications link couples the user access point and the network access point. The communications link is at least partially controlled by the network access point, which monitors information passed between the remote network and the user access point to create an estimate of future usage of the communications link by the user access point based on the information. The network access point allocates communications link resources for the user access point based on the estimate.
[0006] 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, while indicating various embodiments, are intended for purposes of illustration only and are not intended to necessarily limit the scope of the disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The present disclosure is described in conjunction with the appended figures:
[0008] FIG. 1 is a schematic representation of the environment of the network accelerator system according to the present disclosure.
[0009] FIG. 2 is a high level block diagram of an embodiment of a portion of a hub that is relevant to the description of the disclosure.
[0010] FIG. 3 is an exemplary flow chart of the operation of the disclosure of a gateway function.
[0011] FIG. 4 is a flow chart of another embodiment of the operation of the disclosure of the gateway.
[0012] FIG. 5 is a data flow diagram depicting a transaction in which conventional techniques are used to obtain a base HTTP page with two in-line elements.
[0013] FIG. 6 depicts the same transaction as FIG. 5 , except in this scenario, a network access point enhances the process.
[0014] In the appended figures, similar components and/or features may have the same reference label. Where the reference label is used in the specification, the description is applicable to any one of the similar components having the same reference label.
DETAILED DESCRIPTION
[0015] The ensuing description provides preferred exemplary embodiment(s) only, and is not intended to limit the scope, applicability or configuration of the disclosure. Rather, the ensuing description of the preferred exemplary embodiment(s) will provide those skilled in the art with an enabling description for implementing a preferred exemplary embodiment. It being understood that various changes may be made in the function and arrangement of elements without departing from the spirit and scope as set forth in the appended claims.
[0016] Specific details are given in the following description to provide a thorough understanding of the embodiments. However, it will be understood by one of ordinary skill in the art that the embodiments may be practiced without these specific details. For example, circuits may be shown in block diagrams in order not to obscure the embodiments in unnecessary detail. In other instances, well-known circuits, processes, algorithms, structures, and techniques may be shown without unnecessary detail in order to avoid obscuring the embodiments.
[0017] Also, it is noted that the embodiments may be described as a process which is depicted as a flowchart, a flow diagram, a data flow diagram, a structure diagram, or a block diagram. Although a flowchart may describe the operations as a sequential process, many of the operations can be performed in parallel or concurrently. In addition, the order of the operations may be re-arranged. A process is terminated when its operations are completed, but could have additional steps not included in the figure. A process may correspond to a method, a function, a procedure, a subroutine, a subprogram, etc. When a process corresponds to a function, its termination corresponds to a return of the function to the calling function or the main function.
[0018] Moreover, as disclosed herein, the term “storage medium” may represent one or more devices for storing data, including read only memory (ROM), random access memory (RAM), magnetic RAM, core memory, magnetic disk storage mediums, optical storage mediums, flash memory devices and/or other machine readable mediums for storing information. The term “machine-readable medium” includes, but is not limited to portable or fixed storage devices, optical storage devices, wireless channels and various other mediums capable of storing, containing or carrying instruction(s) and/or data.
[0019] Furthermore, embodiments may be implemented by hardware, software, firmware, middleware, microcode, hardware description languages, or any combination thereof. When implemented in software, firmware, middleware or microcode, the program code or code segments to perform the necessary tasks may be stored in a machine readable medium such as storage medium. A processor(s) may perform the necessary tasks. A code segment or machine-executable instructions may represent a procedure, a function, a subprogram, a program, a routine, a subroutine, a module, a software package, a class, or any combination of instructions, data structures, or program statements. A code segment may be coupled to another code segment or a hardware circuit by passing and/or receiving information, data, arguments, parameters, or memory contents. Information, arguments, parameters, data, etc. may be passed, forwarded, or transmitted via any suitable means including memory sharing, message passing, token passing, network transmission, etc.
[0020] In one embodiment of a controlled return link, a hub can monitor data to and from network servers and proactively allocate additional channel capacity to users who are anticipated to transmit further related requests. The following description uses the exemplary application of an Internet web browser using HTTP to connect to Internet servers as an illustrative embodiment of the present disclosure. It can be appreciated that the present disclosure applies to all types of applications employing any of a number of network protocols, as will be clear from the following description.
[0021] When a client (user) browser requests a base file for a web page, the server responds with a file that contains references to in-line objects such as image files that are also part of the page. The client's locally stored cookies, however, may affect what actual objects will end up getting displayed to the client. For example, unique ads or customizations may be made for the particular client. This is one reason why simply applying a pre-fetching system can yield unsatisfactory results. The forward communication link, the hub, the user access point, the Internet, and the network server are all used unnecessarily should pre-fetching gather unneeded information. The client then has to request the needed information anyway since the pre-fetch doesn't gather useful information.
[0022] The environment of the disclosure is shown in FIG. 1 . One or more individual or user sites 104 are connected to a common hub or network access point 120 over a long delay link 116 , for this example, a satellite link 116 . The hub 120 is a central location that serves a gateway function for the individual sites 104 and transmits information to the individual sites 104 either in a common channel or through individual channels in what is called the forward direction. In this example, the forward direction is from the hub 120 , through the satellite relay 116 and to the individual sites 104 . The hub 120 either directly or indirectly controls the link usage of the individual sites 104 , which transmit in what is called the return direction, through the relay satellite 116 and to the hub 120 .
[0023] At the individual site 104 shown (one of many that may be served by the hub 120 ), a number of computers 108 (of potentially different operating systems and configurations) are connected through Ethernet to a user access point 124 that has a satellite modem and includes a number of functions such as network router, etc. The hub 120 is a network access point that relays information between the various users and servers 112 , 128 of interest to those users, the examples given here and any other servers 112 , 128 available to the users through the network access point 120 .
[0024] The hub 120 controls the long delay return link by allocating return channel capacity to users based on some algorithm. This allocation can be tightly controlled such as TDMA reservation, mixed reservation/contention, or as loosely controlled as a completely contention based system. Even in a contention-based system, however, some sort of throttling mechanism is typically employed to keep the network from overloading. Note that the general problem of reserving return channel capacity is a system specific design task that is not detailed in this description, since the subject disclosure can be employed on any sort of controlled return channel.
[0025] The return channel allocation algorithm typically distributes the return channel capacity among users as a function of their priority (e.g., Quality of Service guarantees) and/or their historic usage. In general, a small amount of capacity is reserved for each individual site 104 so that they can at least request more capacity, although these requests can also be accommodated in a contention channel. Due to the random and bursty nature of network accesses, it is difficult to accurately predict the amount of return channel capacity required by an individual site 104 . If an individual site 104 is allocated too much return channel capacity, then it will be able to quickly make any network requests required, but the excess return channel capacity will not be available to other users, resulting in unnecessary delays for them. If not enough return capacity is allocated to an individual site 104 , then it will make its requests slowly and/or use the long delay link 116 to request greater capacity.
[0026] In accordance with the disclosure, a gateway function within the hub 120 monitors the data that flows between individual sites 104 and servers 112 , 128 . With reference to FIG. 2 , a high-level block diagram of the portion of the hub 120 that is relevant to this description of the disclosure is shown. Note that functions such as allocation of the forward channel, etc. are not included for clarity.
[0027] The receiver 210 demodulates the incoming data from the individual sites 104 , extracts the outgoing network traffic and forwards it to a network parser 212 . The size of the data received from the individual site 104 is also passed on to a need estimator 214 , which for example maintains a simple channel usage history of the individual site 104 and delivers the future need estimate to a return channel allocater 216 . In this exemplary implementation, the return channel allocator 216 uses the forward channel transmitter 218 to notify the modems 124 at individual sites 104 of their allocation, although other techniques such as side channels, etc. could alternatively be employed.
[0028] Continuing to follow the path of network traffic in FIG. 2 , the network parser 212 forwards traffic, such as HTTP page requests or other traffic destined for a network 122 , to the router 220 , which fulfills the requests via the network 122 , for example, the Internet. The router 220 also delivers the traffic received from the network 122 to a site parser 224 , which analyses the traffic and forwards the data on to the transmitter 218 for delivery to the appropriate individual sites 104 .
[0029] In one embodiment, a request-based need estimator 226 of the gateway function determines from incoming page requests (from the client at the individual site 104 , forwarded from the network parser 212 ) an estimate of the anticipated future requests of that client. This estimate is then sent to the return channel allocator 216 . This estimate can be based, for example, on keeping a table (either by client or globally) with columns for page (or possibly just for the page server's domain) and expected usage. The table values can be updated in any number of ways. For example, the table could be updated each time a page is accessed, typically employing a smoothing filter that biases toward recent activity.
[0030] In one embodiment, a response-based need estimator 228 determines from server page files (i.e., requested pages coming from the server 112 , delivered from the site parser 224 ) an estimate of the anticipated future requests of that client, which is then sent to the return channel allocator 216 . This estimate can be based on references to in-line elements contained in the response. This can yield an estimate of the future return channel needs, but the gateway function waits for the page request to be filled before making the estimate in this embodiment.
[0031] FIG. 3 is an exemplary flow chart of the operation of one embodiment of the disclosure of the gateway function in the hub portion. The depicted portion of the process starts in step 304 upon receipt of a data request, in this example, a web page request from an individual site 104 . The request is, of course, forwarded on to the network 122 , although not shown in this flow chart. If the page request is new in that the uniform resource locator (URL) or a portion of the URL cannot be matched to another URL as determined in step 308 , then a new page history is opened for the requested page in step 316 . In some embodiments, URLs may be deemed to match where there isn't an exact match as metadata in the URL can cause matching to be difficult. Note that the page history is subject to time-out for a number of reasons including limited storage space at the gateway. Obviously, older page histories are less relevant and would be targeted for replacement if there were a table space allocation issue, although certain high priority clients and/or servers 112 and their associated page histories could be maintained as desired. When a page history times out, it is removed from a table or database holding the page history.
[0032] If a new page history is opened, then a default return channel need profile is generated. This profile could be null, but would ideally represent a level of need that would give an individual user a reasonable level of service without overloading the return channel if a large number of users were granted the capacity simultaneously. The level of need could be an average for the domain of the URL, a portion of the URL and/or all domains. The sole table shows allocation for particular pages. In this simplified example, profiles for four web pages are stored such that requests for those pages results in an increase in the allocation for the return direction to service the requests likely to follow the web page.
[0000]
TABLE
Allocations for Pages
Web Page
Allocation in Kbps
realure.com/acme.htm
30
nesbittea.org/contact.htm
80
lucenarity.info/sitemap.htm
10
videodlserver.com/spec.html
200
[0033] If the page request is not new, then a page history already exists and is looked up in step 312 . This history can be of a number of equivalent forms: average bit rate needed versus time, specific burst times and sizes, etc. Page histories can be maintained on an individual user basis, individual site basis and/or system-wide. For example, the system-wide average return channel capacity requirement could be employed for a user upon first viewing of a web page that had previously been visited by other users. As the user continues to revisit the page, the usage history would then determine the allocation required.
[0034] The estimated needs for the subject individual site 104 is modified in step 320 by the estimate derived above. This estimate is then input into the return channel allocation algorithm and added to the allocation for the individual site 104 in step 328 if the capacity is available on the return channel (RC) as determined in step 324 . This embodiment may wait for the web page to be returned to the hub 120 before modifying the RC allocation for the individual site 104 or could have the change become effective at a time relative to when the user access point 124 receives the web page, but other embodiments could send a message to the modem 124 to increase the RC allocation once the request is correlated to others. One embodiment tries to predict when the return channel will receive the requests for the in-line objects and has the RC allocation timed to coincide with that event. Note that any of a number of known techniques can be used to allocate the capacity, as mentioned previously.
[0035] FIG. 4 is a flow chart of an embodiment that uses a response-based need estimator 228 to determine from server page files (i.e., requested pages coming from the server 112 , delivered from the site parser 224 ) an estimate of the anticipated future requests of that client, which is then sent to the return channel allocator 216 . After data is received from the server 112 in step 404 , it is relayed on the forward satellite channel to the client modem 124 . The page is also parsed by the site parser 224 in step 408 to determine if there are any in-line objects, etc. that indicate potential user return channel needs in step 412 . A typical application of the algorithm would be to count the number of inline items, estimate the return channel capacity needed to request each one, and then total the estimates. The needs table for that individual site 104 , discussed previously, would then be updated accordingly in step 416 . Finally, as in the previous embodiment, the needs for this individual site 104 would be integrated together with the needs from all the other sites 104 to determine the return channel allocation in steps 420 and 424 . For example, a large need of one individual site 104 may not be completely allocated where other sites 104 are consuming a large portion of the channel.
[0036] FIG. 5 depicts data flows for a transaction in which conventional techniques are used to obtain a base HTTP page with two in-line elements. Message transfers are depicted by lines that slope downward with the flow of time where the longer a transfer takes the steeper its slope. The process starts with a user requesting a base page in step 504 , which goes across the long-delay satellite link 116 to the network access point or hub 120 . Note the significant slope of the ‘HTTP GET BASE’ line 504 , because of the delay of the link 116 . The network access point 120 then quickly obtains the resulting page from the network 122 , depicted by the looping line that returns quickly (in a short distance down the page) to the network access point 120 . The network access point 120 then forwards the base page from the server 112 to the user in step 508 , again on the long-delay link 116 .
[0037] In this example, the user only has capacity to request a single item per round-trip period, so after a short processing delay, the user requests the first in-line element of the base page via the ‘HTTP GET IN-LINE 1 ’ request 512 . The network access point 120 then quickly obtains the resulting in-line element from the network, depicted by the second looping line that returns quickly (in a short distance down the page) to the network access point 120 . The network access point 120 then forwards the in-line element to the user in step 516 , again on the long delay link 116 . After a short processing delay, the user requests the second in-line element of the base page via the ‘HTTP GET IN-LINE 2 ’ request 520 . The network access point 120 then quickly obtains the resulting in-line element from the network, depicted by the third looping line that returns quickly (in a short distance down the page) to the network access point 120 . The network access point 120 then forwards the in-line element to the user in step 524 , again on the long delay link 116 .
[0038] Note that in this example, even if the user were able to request additional capacity from the network access point 120 , any response would not arrive much before the first in-line element, thus making the request moot, since after arrival of the first in-line element, the user would be able to request the second and final in-line element anyway. The web browser or other application software of the user's computer 108 renders the base page and in-line elements as they are received.
[0039] FIG. 6 depicts the same transaction as FIG. 5 , except in this scenario, the network access point 120 is able to accurately estimate the user's need to request in-line elements, through request-based and/or response-based need estimators 226 , 228 . Here as in FIG. 5 , the user request 504 is made at the upper left corner of the figure. Once the base page is received by the network access point 120 in step 504 , however, the network access point 120 detects the referenced in-line elements and sends an additional message 612 to the individual site 104 , increasing the return channel allocation for the anticipated requests. Both ‘HTTP GET IN-LINE’ requests 616 , 620 are then sent subsequently via the increased return channel capacity. The requests 616 , 620 are forwarded on to the Internet 122 by the network access point 120 and fulfilled shortly thereafter. Finally, both in-line elements are delivered to the user. In this illustrative example, approximately one round trip delay time (from the user to the network access point 120 and back) is saved versus the technique of FIG. 5 .
[0040] The example illustrated in FIG. 6 is greatly simplified. As a particular modem or user access point 124 can service a number of computers 108 and devices making content requests from the network. The content requests from the individual site 104 are each analyzed and the additional return allocation is communicated to the modem 124 . In this way, the content requests are aggregated to step-up or step-down the return allocation for each modem 124 in the system.
[0041] The techniques described herein may be implemented by various means. For example, these techniques may be implemented in hardware, software, or a combination thereof. For a hardware implementation, the processing units within a hub 120 or a modem 124 may be implemented within one or more application specific integrated circuits (ASICs), digital signal processors (DSPs), digital signal processing devices (DSPDs), programmable logic devices (PLDs), field programmable gate arrays (FPGAs), processors, controllers, micro-controllers, microprocessors, other electronic units designed to perform the functions described herein, or a combination thereof.
[0042] For a software implementation, the techniques, processes and functions described herein may be implemented with modules (e.g., procedures, functions, and so on) that perform the functions described herein. The software codes may be stored in memory units and executed by processors. The memory unit may be implemented within the processor or external to the processor, in which case it can be communicatively coupled to the processor via various means as is known in the art.
[0043] While the principles of the disclosure have been described above in connection with specific apparatuses and methods, it is to be clearly understood that this description is made only by way of example and not as limitation on the scope of the disclosure. | A communication system for providing network access over a shared communication link is disclosed. The communication system includes a user access point, a network access point and a communications link. The user access point is coupled to one or more user terminals that access a remote network. The network access point is coupled to the remote network. The communications link couples the user access point and the network access point. The communications link is at least partially controlled by the network access point, which monitors information passed between the remote network and the user access point to create an estimate of future usage of the communications link by the user access point based on the information. The network access point allocates communications link resources for the user access point based on the estimate. | 7 |
TECHNICAL FIELD
This invention relates to an adjustable holding device for automobiles for holding personal effects.
BACKGROUND
Drivers and passengers in an automobile almost always carry some personal items with them during a trip or commute, and laying the personal items in a nearby seat or floor is undesirable. Under many circumstances, it would be desirable to hang the items up somewhere in the vehicle, but usually there are only a very limited number of places to hang an item. Most vehicles are equipped with an integrated hanger located above the rear side window, but hanging an article on such a hanger may block the driver's or passenger's field of view and normally places the item out of the reach of the driver during a trip or commute. The driver or passenger may also try to hang an item around one of the front seats or headrests, but this too could inadequate, since it may be inconvenient or uncomfortable for the person sitting in the seat and some personal effects simply cannot fit around these structures.
Other hanging systems for automobiles rely on inconvenient and extensive attachment mechanisms. The simpler attachment mechanisms require removal of the headrest for installation. Still others are bulky, metallic devices to withstand the weight of large heavy items and are inconvenient for normal articles that are carried on a day-to-day basis. The smaller, more convenient hanging devices do not possess the proper leverage to withstand heavier items.
For the foregoing reasons there is a need for a holding device for automobiles that is simple to install, convenient to use, aesthetically pleasing, and not cumbersome.
SUMMARY
The present invention is directed to a holder for personal effects in a vehicle. The holder comprises a base that fits around the support rods of a headrest, a mount that may adjustably connected to the base and designed to hold the strap or other hanging feature of one or more personal items, and at least one securement block that may be used to sure up the base, limit its ability to move laterally, or help it to support heavier items.
In some embodiments, the base may be detachable and reversible so that it can be used in combination with the headrest support rods of a seat on either side of the car and so that the arm can be positioned in a maximum number of variations for the convenience of the user. In some embodiments, one or more of the securement blocks is easily removable and re-attachable to the base to accommodate a large variety of headrest and support rod configurations.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a perspective view of one embodiment within the scope of the present invention;
FIG. 2 is an exploded perspective view of one such embodiment; and
FIG. 3 is a side view of an embodiment in keeping with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The detailed description set forth below in connection with the appended drawings is intended as a description of presently-preferred embodiments of the invention and is not intended to represent the only forms in which the present invention may be constructed or utilized. The description sets forth the functions and the sequence of steps for constructing and operating the invention in connection with the illustrated embodiments. It is to be understood, however, that the same or equivalent functions and sequences may be accomplished by different embodiments that are also intended to be encompassed within the spirit and scope of the invention.
The present invention is versatile article holder 100 for use in automobiles. Referring to FIG. 1 , the holder 100 can be secured between a backrest 10 and a headrest 12 of an automobile seat where it can provide a means for holding various articles, such as clothes, bags, purses, and the like. Referring to FIGS. 1 and 2 , the holder 100 of the present invention comprises a base 102 , an arm 104 protruding from the base 102 , a mount 107 movably connected to the arm 104 , and at least one securement block 106 attachable to the base 102 . In general, the base 102 provides the foundational support for the mount 107 , the arm 104 provides an extension from the base 102 to increase range and versatility of the holder 100 , the mount 107 provides the means for holding an article, and the securement block 106 helps secure the base 102 in place.
The base 102 comprises a longitudinal axis 16 , a first end 108 , a second end 110 opposite the first end 108 , and a middle portion 112 in between the first and second ends 108 and 110 . The base 102 may be constructed of any sturdy and durable material such as plastic, wood, metal, and the like. The middle portion 112 comprises a first and second side having interior edges defining a gap 118 . The first end 108 comprises an opening 114 . Preferably, the opening 114 is a wedge-shaped opening or a “V”-shaped opening that ends at a split 116 in the base 102 leading into the gap 118 in the middle portion 112 . The “V”-shaped design allows the support rods of a headrest, or rods 14 , of a headrest 12 to be guided easily into the opening 114 where the support rods or rods 14 can be pushed passed the split 116 at the vertex of the “V” or wedge. As the rods 14 are pushed deeper into the “V” or wedge 114 , the rods 14 gradually open the split 116 . Once it has passed the split 116 , the rods 14 become “trapped” in the gap 118 as the ledges 120 on the opposite side of the wedge prevents the rods 14 from passing back out of the gap 118 in the opposite direction.
In some embodiments, the opening 114 may have a closure 15 . The closure may be a bar, rod, strap, clamp, elastic band, and the like to keep the split 116 in a closed state to facilitate the prevention of the base 102 from slipping out from the headrest rods 14 .
Preferably the gap 118 is along the longitudinal axis 16 , thereby separating the middle portion 112 into the first side 122 and second side 124 . The width of the gap 118 is such that a headrest rod 14 can fit tightly inside the gap 118 . In some embodiments, the gap 118 may have a means for conforming to the shape of the headrest rods 14 . For example, the gap 118 may be ribbed with semi-circular concavities so as to allow cylindrical headrest rods 14 to fit inside the concavity. In some embodiments, the first and second sides 122 , 124 may be lined with a plastic or elastic deformable material, such as foam, neoprene, rubber, and the like on the sides defining the gap 118 to sandwich or clamp the rods 14 between the two sides 122 and 124 with the closure 15 or the securement block 106 .
In some embodiments, the first and second sides 122 and 124 of the middle portion 112 may be aligned with holes 126 . Preferably, the holes 126 on the first side 122 are paired with holes 126 on the second side 124 . These holes 126 may be through holes or incomplete holes, such as a divet or an indentation. In some embodiments, the holes 126 may be along the inner or outer edges of the first and second sides 122 , 124 . These holes 126 provide a means for fixing the securement blocks 106 in place. Therefore, the holes may be any geometric shape such as circular, ovoid, square, rectangular, triangular, star-shaped, and the like that can mate with a reciprocal peg or locating pin having the same shape. In some embodiments, the holes 126 may be elongated slots in which the locating pins can slide.
The second end 110 of the base 102 connects with the arm 104 . The arm 104 comprises a proximal end 128 connected to the second end 110 of the base 102 , and a distal end 130 opposite the proximal end 128 . The distal end 130 may have a first orifice 132 through which the mount 107 may be adjustably attached.
In some embodiments, the arm 104 is integrally connected to the second end 110 of the base 102 , thereby forming a single piece. In such embodiments, the arm 104 may be angularly offset from the longitudinal axis 16 . In other words, the arm 104 may be bent relative to the base 102 . This angular offset increases the versatility of positioning the article.
In some embodiments, the arm 104 may be adjustably attached to the base 102 . For example, the arm 104 may be attached to the base 102 by a swivel, a hinge, a joint, or the like to allow lateral, vertical, or rotational movement. For example, the arm 104 can be rotated so as to be at right angles to the base 102 , then swiveled downward so as to be parallel to the backrest 10 . This positions the mount 107 closer to the floor so that heavier items with handles may rest on the floor but have their handles hooked onto the mount 107 to reduce sliding of the item across the floor and to make it easier to grasp the handles of the items for removal. In some embodiments, the arm 104 may be telescopic so as to adjust the length of the arm 104 to further increase the versatility of placement of the article.
The article hangs from the mount 107 . The mount 107 may be movably connected to the distal end 130 of the arm 104 . The mount 107 comprises a base wall 134 having a first surface 136 and a second surface 138 opposite the first surface 136 . The first surface 136 may have a crook 140 so as to form a hook in conjunction with the first surface 136 . In some embodiments, the first surface 136 may have a “T”-shaped crook 140 extruding from the first surface 136 , thereby creating a double hook. The double hook facilitates the reversibility of the holder 100 . In some embodiments, the mount 107 may be fixedly attached to the arm 104 or even integrally formed with the arm 104 .
The second surface 138 may have a flange 142 extruding therefrom. The flange 142 may have a second orifice 144 that can align with the first orifice 132 of the arm 104 . A bolt 146 may be inserted through first and second orifices 132 and 144 to secure the mount 107 to the arm 104 with a nut 148 . Using a bolt 146 and nut 148 fastener allows the mount 107 to swivel, thereby creating a swivel hook. The nut 148 also serves as a clamp that may be tightened or loosened to immobilize or make rotatable, respectively, the swivel hook. Other fasteners known to those skilled in the art may be used to create a swivel hook. The mount 107 may have a washer 150 positioned between the nut 148 and the flange 142 to facilitate movement. In some embodiments, the washer 150 may be a shake-proof washer to absorb unwanted movements and vibrations.
Besides a nut 148 and bolt 146 , the mount 107 may be fastened to the arm 104 in a variety of ways. For example, the mount 107 may be clamped on, screwed on, stuck on with adhesives, or fit on with resistance.
The securement block 106 secures the holder 102 in place on the backrest 10 of a seat with the aid of the headrest rod 14 and the headrest 12 . The securement block 106 is a sturdy block of material that is positioned adjacent to a headrest rod 14 , on top of or underneath the holder 100 , and sandwiched between the headrest 12 and the backrest 10 . The securement block 106 utilizes the compressive force exerted upon it by the headrest 12 to secure the holder 100 on to the backrest 10 and restrict vertical movement of the holder 100 . Examples of material suitable for use as a securement block 106 include durable, pliable material, such as neoprene, foam, cork, rubber, and the like, or harder material, such as plastic, wood, metal, and the like.
In some embodiments, the securement block 106 comprises a fastening means 152 to fasten the securement block 106 to the base 102 . The fastening means 152 may be a lockbar 153 with locating pins 154 . The securement block 106 may be fastened to the lockbar 153 by a variety of means. Preferably, adhesives are used to fasten the securement block 106 to the lockbar 153 . The locating pins 154 may be configured to fit resistively into the pair of holes 126 on the first and second sides 122 and 124 of the middle portion 112 of the base 102 . The resistance or pressure created by forcing the locating pins 154 into the holes 126 creates a secure attachment, yet allows for quick and easy removal and attachment. Installation and removal of the securement blocks does not require removal of the headrest rods or any additional tools. Thus, the holder 100 can easily be adjusted to fit headrest holder of a variety of shapes and sizes, including non-traditional headrest rods, such as single block or elongated headrest rods. Using the securement blocks 106 also allows the holder to be quickly moved from seat to seat or from one orientation to another orientation. Thus, the mount may be positioned on the left or right sides of the car (laterally) or in the middle of the car (medially) from the driver's or passenger's seat.
In some embodiments, the locating pins 154 may have a longitudinal split 156 to allow the locating pins 154 to be compressible to facilitate insertion into the hole pair 126 . In some embodiments, the locating pins 154 may be tapered to facilitate insertion into the holes pair 126 . The securement block 106 can be moved along the base 102 and fit into any hole pair 126 to secure the securement block 106 . The ease with which the securement blocks 106 can be moved improves the adjustability of the holder 100 , thereby improving the variability of the overhang of the mount 107 off the backrest 10 .
In some embodiments, locating pins 154 may protrude directly from the securement blocks 106 without the need for a lockbar 153 . In some embodiments, the fastening means 152 may be a clamp, a clip, a bracket, a band, a magnet or any other fastener that can reversibly fasten the securement block 106 to the base 102 while immobilizing the first and second sides 122 and 124 relative to each other. For example, the fastener 152 may be a C-shaped clamp or bracket type device that clamps or fits around the outer edges of the first and second sides 122 and 124 . In such embodiments the holes 126 would not be required on the first and second sides 122 and 124 and the securement block 106 could slide along the base 102 to be placed in the desired position.
In use, the holder 100 is passed along the backrest 10 so that the headrest rod 14 is passed through the opening 114 into the gap 118 to the desired position. Once the holder 100 is in position, at least one securement block 106 is inserted in between the holder 100 and the headrest 12 that is supported by the headrest rod 14 . Preferably, the securement block 106 is positioned adjacent to the headrest rod 14 so that the securement block 106 prevents movement in at least one direction. The securement block 106 may be placed below the holder 100 between the holder 100 and the backrest 10 or above the holder 100 between the holder 100 and the headrest 12 . In some embodiments, two or more securement blocks 106 and 106 ′ may be utilized in a variety of configurations to secure the holder 100 . For example two securement blocks 106 and 106 ′ may be positioned on opposite sides but adjacent to the same headrest rod 14 . If there are two headrest rods 14 and 14 ′, the securement blocks 106 and 106 ′ may be placed on the outer sides but adjacent to the two headrest rods 14 and 14 ′, on the inner sides but adjacent to the headrest rods 14 and 14 ′ or the same sides of the different headrest rods 14 and 14 ′. This reduces any lateral movement along the longitudinal axis 16 as any lateral movement in a first direction will be blocked by the first securement block 106 and any lateral movement in a second direction will be blocked by the second securement block 106 ′. A single securement block 106 may be used to buttress against a first headrest rod 14 and the second headrest rod 14 ′ may be buttressed against the ledges 120 at the first end 108 or the second end 110 of the middle portion 102 .
Once the securement block 106 is positioned, the headrest 12 can be lowered onto the securement block 106 to secure the securement block 106 . The force created from the headrest 12 compressing the securement block 106 against the backrest 10 provides the resistance to keep holder 100 on the backrest 10 and limit vertical movement of the holder 100 . With the securement block 106 in place, the article can be hung on the mount 107 .
In some embodiments, the securement block 106 may be placed underneath the holder 100 between the holder 100 and the backrest 10 rather than on top of the holder. In some embodiments, the securement blocks 106 may be placed underneath and on top of the holder 100 to raise the headrest to a higher position to accommodate taller individuals.
In some embodiments, an additional securement block 106 ″ may be used to increase the support provided by the holder 100 . For example, a third securement block is 106 ″ may be positioned anywhere under the headrest 12 . In some embodiments, the additional securement block 106 ″ may be positioned underneath the holder 100 buttressed against the shoulder 18 of the backrest 10 to provide additional support for the arm 104 . In some embodiments, the additional securement block 106 ″ may be configured to conform to the shoulder 18 of the back seat as shown in FIG. 1 so as to reduce forward and backward movement of the holder 10 . For example, the block portion or foundation of the securement block may be curved or concave to conform to the curvature of the shoulder 18 of the backrest 10 .
To accommodate different height positions of the headrest, the securement blocks 106 may come in variety of dimensions. In addition, the height of the headrest may be adjusted by placing a first securement block 106 above the holder and a second securement block 106 ′ below the holder directly underneath the first securement block 106 so as to stack the securement blocks 106 , 106 ′ to raise the headrest 12 .
To remove the holder 100 , the headrest 12 is raised, the securement block 106 is removed, the first and second sides 122 , 124 are slightly spread apart so that the headrest rod 14 can be slipped past the ledges 120 at the split 116 .
Due to the flat characteristic of the holder 100 , the holder 100 can be reversible. Thus, in embodiments with a fixed, bent arm, 104 the holder 100 can be flipped 180 degrees about the longitudinal axis 16 onto the opposite side if the user wants the bent arm 104 pointing in the opposite direction. In embodiments having a double hook, no further modifications need to be made on the mount 107 . In embodiments with a single hook, the mount 107 can be removed easily and re-mounted on the opposite side. The features of the holder 100 also allow the holder to be rotated 180 degrees about an axis perpendicular to the longitudinal axis so that the arm may be directed medially or laterally relative to the car.
The foregoing description of the preferred embodiment of the invention has been presented for the purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Many modifications and variations are possible in light of the above teaching. It is intended that the scope of the invention not be limited by this detailed description, but by the claims and the equivalents to the claims appended hereto.
INDUSTRIAL APPLICABILITY
This invention may be industrially applied to the development, manufacture, and use of a holder 100 for automobiles for the purpose of easily and conveniently hanging articles in an automobile. Such a holder 100 comprises a base 102 having a longitudinal axis 16 , the base 102 comprising a first end 108 , a second end 110 opposite the first end 108 , and a middle portion in between the first end 108 and the second end 110 . The first end 108 comprises a split 116 through which the holder 100 can be mounted onto a headrest rod 14 . The middle portion 112 comprises a gap 118 , separating the middle portion 112 into a first side 122 and a second side 124 in which the headrest rods 14 reside. An arm 104 protrudes from the second end 110 of the base 102 to provide clearance from the seat from which the holder 100 is supported. A mount 107 from which the articles may hang is movably connected to the arm 104 . At least one securement block 106 is used to secure the holder 100 on the headrest rod 14 to provide a means to withstand the weight of heavier items.
While the present invention has been described with regards to particular embodiments, it is recognized that additional variations of the present invention may be devised without departing from the inventive concept. | A holder for personal effects in a vehicle comprising a base that fits around the support rods of a headrest, a mount that may adjustably connected to the base and designed to hold the strap or other hanging feature of one or more personal items, and at least one securement block that may be used to sure up the base, limit its ability to move laterally, or help it to support heavier items. The base may be detachable and reversible so that it can be used in combination with the headrest support rods of a seat on either side of the car and so that the arm can be positioned in a maximum number of variations for the convenience of the user. In some embodiments, one or more of the securement blocks is easily removable and re-attachable to the base to accommodate a large variety of headrest and support rod configurations. | 1 |
CROSS REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part application of U.S. patent application Ser. No. 10/905,826 filed Jan. 21, 2005, currently pending.
BACKGROUND OF INVENTION
1. Field of Invention
This invention relates generally to indoor/outdoor area rugs or mats and, more particularly, to bamboo area rugs.
2. Background Art
Bamboo is a grass, that belongs to the sub-family Bambusoidae of the family Poaceae (Graminae). Bamboo occurs naturally on every industrialized and populated continent with the exception of Europe. There are over 1000 known species of bamboo plants. It is a durable and versatile material, that has been utilized by various cultures and civilizations for various applications. Bamboo has been an integral part of the cultural, social and economic traditions of many societies. There is a vast pool of knowledge and skills related to the processing and usage of bamboo, which has encouraged the use of bamboo for various applications.
Clumping bamboo can be widely grown in tropical climates. The trunk of the plant is called the “culm”. The culm is wider at the trunk or bottom and narrows toward the top. In some varieties of bamboo the culm may grow 40 to 60 feet tall. Once established, bamboo plants can replenish themselves in two or three years. Each year a bamboo will put out several full length culms, that are generally hollow, in the form of a tube having “nodes”. There are other parts of the bamboo plant that can be utilized other than the culm, including commonly used parts of a bamboo such as branches and leaves, culm sheaths, buds and rhizomes. Some species are very fast growing at the rate of one metre per day, in the growing season.
As mention above, bamboo occurs naturally on most continents, mainly in the tropical areas of a given continent. Its natural habitat ranges in latitude from Korea and Japan to South Argentina. It has been reported that millions tons of bamboo are harvested each year, almost three-fifths of it in India and China. One known source of quality bamboo is found in the Anji Mountains of China.
Bamboo has many uses such as substituting commercially for wood, plastics, and composite materials in structural and product applications. There is a large diversity of species, many of which are available in India, which is the second largest source of bamboo in the world ranking only behind China. These grow naturally at heights ranging from sea level to over 3500. Most Indian bamboo is sympodial (clump forming); the singular exception is Phylostacchus bambuisodes, cultivated by the Apa Tani tribe on the Ziro plateau in Arunachal Pradesh.
A common application for bamboo-based products is to utilize bamboo as a wood substitute. These applications include boards of various size and specifications and uses—laminates, flooring, panels, particleboard, insulation material, chipboard, wafer board, woven mat-board, bamboo ply-substitutes and veneer. Bamboo is in many respects, stronger than many wood products, and is comparable for some critical parameters with even some hardwoods. Bamboo laminates could replace the use of wood in many applications mostly including building and construction. Thin walled bamboo species may not be suitable for boards/laminates, but the thick walled bamboo is suitable. There are various thick walled bamboo species like tulda.
Bamboo has to undergo certain processing stages to convert them into boards/laminates. The green bamboo culms are converted into slivers/slats and then to boards. The boards are finally finished by surface coating. The common primary processing steps for making sliver/slats from green bamboo culms are 1. Cross Cutting; 2. Radial Splitting; 3. Internal Knot Removing & Two-side Planing; 4. Four-side Planing; and 5. forming slivers/slats. The common secondary processing steps for making board/laminate from slivers/slats are 1. Starch Removal & Anti-fungal Treatment; 2. Drying; 3. Resin Application; 4. Laying of Slivers/Slats; 5. Hot Pressing & Curing; and 6. form Laminates/Boards. The common surface coating and finishing stages are 1. Surface Sanding & Finishing; 2. Surface Coating with melamine/polyurethane; 3. Curing of Laminate; 4. Fine Sanding; 5. Evaluation of Surface Properties.
There are various types of bamboo flooring including tongue and groove and the type that needs to be butted together. The lacquered flooring tiles are finished using wear resistant UV lacquer and the unlacquered flooring tiles need to be coated/waxed and polished after installation. The strength of Bamboo Boards can be better than common wood board for its special Hi-steam pressure process. The board has good water resistance for its shrinking and expanding rate. Its water-absorbing rate is better than wood and is further humidity resistant and smooth. It has been reported that the strength of 12 mm bamboo ply-board is equivalent to that of a 25 mm plywood board.
There are also various types of bamboo area rugs made of flat elongated slats or strips arranged side by side length wise and having thread woven around and between the strips binding them together in a side by side arrangement. There is also usually a cloth or felt backing or some other fibrous material bonded to the underside. The bamboo area rugs also usually have a boarder edge binding made of cloth or other durable fibrous material.
The bamboo material is very durable for an area rug application, however, the construction of many bamboo rugs are lacking and the indoor/outdoor capability is limited. A novel bamboo area rug construction is needed.
BRIEF SUMMARY OF INVENTION
The invention is a bamboo Indoor/Outdoor Area Rug that is manufactured from 100% Anji Mountain bamboo from China. The bamboo is all treated with various protective coatings to add resistance to natural factors including water, sun and dirt. All bamboo rugs manufactured for outdoor/indoor use are made from the harder portions of the bamboo trunk. (Some bamboo used for indoor purposes only are manufactured from the softer fibers of the inside of the bamboo trunk). This portion of the bamboo trunk is not utilized for this invention. The bamboo utilized in the present invention is taken from the harder part of the bamboo trunk to assure maximum endurance and longevity. The lower trunk portion of the bamboo plant is harder and less porous. Anji Mountain Bamboo is the only bamboo that is grown in a climate where there is a ‘winter freeze’ that causes the tree to go dormant with no sap or growth throughout the winter. This causes the tree to become harder than bamboo trees grown in areas that remain warm and moist throughout the year with no chance for the bamboo to go through the seasonal changes that allows for harder and tighter fibers created during the dormant stages our Anji Mountain Bamboo trees experience each winter.
The bamboo for the present invention is kiln dried to prevent warping and remove moisture that can cause future warping. Certain styles of bamboo are oxidized in a boiling vat of liquid to bring out different variations of color vs. the common method of spray staining the bamboo slats to a particular color. The oxidation process also makes the bamboo less porous to moisture. The bamboo is assembled with slats laying next to one another and then assembling in a rug or carpet loom using poly resin fibers, fibrous tape strips, interwoven nylon fibers and/or other fibers, to avoid rot, mold, mildew and decay. During the assembly process in the loom a poly mesh sheet is placed on the bottom side of the rug. A mastic layer is then placed over the poly mesh sheet before a final layer of high density jute or coconut fiber is applied, which is preferably about approximately 2 mm in thickness. Then the rugs are cut to the desired dimensions and a boarder is bonded about the perimeter. The boarder is preferably made of polypropylene or other like material and the boarder is preferably sewn using poly thread or like material. The boarder material is preferred in order to avoid problems with rot, mildew and decay.
The present Outdoor/Indoor Bamboo Area Rug can be manufactured with either a coconut fiber backing or a jute backing. Both of these backings are natural fibers that are resistant to mold, mildew and decay. The coconut fiber and jute fiber backing is processed into a porous matting that allows for natural drainage of water and allows for easy evaporation of moisture that is a primary cause of mold and mildew created in the felt backing or solid resin backing that is most commonly used as a padding surface for bamboo area rugs or most area rugs for that matter. Alternatively, a non-slip backing as described herein can be utilized in lieu of the natural fiber backing or in addition to the natural fiber backing by applying to the underside of the fiber backing. Certain bamboo that is used in the manufacture of the present Outdoor/indoor Bamboo Area Rug is oxidized and gives it an extra step in making the bamboo more impermeable to water, sunlight and dirt. Once the elongated bamboo strips have been processed, they are adjacently aligned lengthwise, and side by side. A fiber mesh sheet is applied and bonded to the underside to hold the strips together. Then the porous mating is bonded to the underside. The present inventions construction provides a product that is resistant to damage from rain, rot, mold, mildew and decay.
These and other advantageous features of the present invention will be in part apparent and in part pointed out herein below.
BRIEF DESCRIPTION OF THE DRAWINGS
For a better understanding of the present invention, reference may be made to the accompanying drawings in which:
FIG. 1 is a perspective exploded partial cut away view of the bamboo rug layers without the border; and
FIG. 2 is a perspective partial cut away view of the bamboo rug assembled with a border.
DETAILED DESCRIPTION OF INVENTION
According to the embodiment(s) of the present invention, various views are illustrated in FIG. 1-2 and like reference numerals are being used consistently throughout to refer to like and corresponding parts of the invention for all of the various views and figures of the drawing. Also, please note that the first digit(s) of the reference number for a given item or part of the invention should correspond to the Fig. number in which the item or part is first identified.
One embodiment of the present invention comprising bamboo slats and a jute or coconut fiber backing teaches a novel apparatus and method for an outdoor/indoor bamboo rug that is resistant to moisture.
The details of the invention and various embodiments can be better understood by referring to the figures of the drawing. Referring to FIG. 1 , a perspective exploded partial cut away view of the present invention's bamboo rug layers without the border is shown. The outdoor/indoor area rug 100 is shown without a border and with the layers revealed in an exploded view. The rug 100 comprises a plurality of elongated flat bamboo slats 102 arranged lengthwise and side by side and each slat connected in a substantially abutting relationship with respect to an adjacent slat forming a seams 114 between adjacent slats. The connected slats form the bamboo rug portion 104 (bamboo layer). The abutting edges of adjacent slats can be unattached.
The adjacent slats can be connected to each other on the rug's bamboo layer underside 108 (the underside of the slats) by at least one loom fibrous tape strip extending orthogonally with respect to the lengthwise extension of the slats, see item 210 of FIG. 2 , using a loom system forming a rug. The loom fibrous tape strip can have some adhesive or adhesion properties on at least one facing surface of the tape strip such that it bonds to the underside of the slats to connect the adjacent slats together from the underside of the slat. The strip can extend orthogonally with respect to the lengthwise extension of the slats and can extend edge to edge of the bamboo layer portion 104 .
Alternatively or in addition to continuous fibers can be woven extending orthogonally around and between each of the slats connecting the slats together. Also, the slats can be connected by a series of substantially parallel fibers having adhesive properties extending orthogonally with respect to the lengthwise extension of the slates. The connecting tape strips or fibers 210 can also extend in a crossing angular fashion with respect to the lengthwise extension of the seams 114 . A fiber mesh sheet 106 can then be applied on the rug's underside 108 . The mesh sheet further bonds the bamboo slats together.
A resin material layer applied to the fiber mesh sheet underside 110 bonding the mesh sheet to the underside of the rug's bamboo layer. The resin material can be for example a mastic resin layer. The mastic resin layer will assist in providing a moisture seal for the underside of the rug for outdoor usage as well as bond the mesh sheet to the bamboo slats' underside 108 . Then a high density layer 112 of matted natural fiber is applied to the mesh sheet underside 110 . The resin layer assists in bonding the natural fiber layer to the mesh underside. The natural fiber layer can be moisture and mildew resistant for outdoor usage. The natural fiber layer can be made of matted jute bonded under and to the resin material layer or the fiber layer can be matted coconut fiber. Jute and coconut fiber have moisture and mildew resistance characteristics, thus can be for outdoor as well as indoor usage. One embodiment of the natural fiber layer can be about approximately 2 mm in thickness. However, the thickness of the natural fiber layer can vary significantly depending on the application and the environment for which the rug is to be used.
Alternatively, the layer described above as the high density layer 112 of matted natural fiber can alternatively be replaced by a non-slip, indoor-outdoor baking layer that is weather/moisture resistant and made from polypropelene/PVC formed into a blended rug mat and made with an open weave that allows ventilation for evaporation of moisture. Yet another embodiment could be to apply this polypropylene/pre-layer under the natural fiber layer as described above. See 107 in FIG. 1 . This eliminates the need for a user to have a separate non-slip rug pad as a separate under layment and makes the bamboo rug appropriate for indoor and outdoor use. The non-slip backing can be manufactured from a non-skid polypropvlene/PVC or like material blended rug mat with an open weave that allows ventilation for moisture evaporation, perfect for outdoor application. The bamboo rug can be manufactured with an actual non-skid rug pad for indoor use so that a separate non-skid pad does not have to be purchased by the retail consumer. The non-slip mat also takes away the need for the Retail Customer to purchase a non-slip rug pad as a separate purchased item when the rug is purchased for Indoor or Outdoor use.
Referring to FIG. 2 , the layers are shown assembled together forming the bamboo rug with a border 200 . Once the layers are assembled, a fibrous material border 202 can be folded about and attached around the perimeter of the rug edges 208 . The border 202 can be attached on the rug top surface 204 and then wrapped about the rug edges 208 around and attached to the bottom rug surface 206 . The border can be attached by stitching completely through the border material and all of the rug layers.
Alternatively, the borders 202 described above as being made of fibrous material can be made of polypropelene, which is resistant to mold, mildew and decay as it is exposed to moisture and the natural elements.
The rug as described herein can be such that the bamboo slats are kiln dried to prevent warping. The rug as described can also be such that the bamboo slats are oxidized in a boiling vat of liquid for coloring the bamboo rather than performing a staining process. The rug as described, can have a resin layer that is a mastic resin layer for sealing and moisture resistance. The rug invention as described herein can be such that the bamboo slats are made of the harder lower trunk portions of the bamboo plant. The loom fiber such as the fibrous tape strip, can be a poly resin fiber.
The fiber mesh sheet can also be a poly fiber mesh sheet, as well as the fibrous material border can be made of polypropylene and attached around the perimeter of the rug with a poly thread sewn stitch. This polypropylene border embodiment provides a significant moisture barrier assisting in preventing moisture penetrating between the layers of the rug.
All of these features provide significant moisture mildew resistance, therefore, providing a bamboo rug with good outdoor characteristics. The construction of the layers bonded under the bamboo slats provide strength and durability as well as characteristics for outdoor usage. The construction and the material contained in the construction described herein also provide substantial flexibility such that he rug can be easily rolled up.
The various bamboo rug examples shown above illustrate a novel outdoor/indoor bamboo rug construction. A user of the present invention may choose any of the above bamboo rug construction embodiments, or an equivalent thereof, depending upon the desired application. In this regard, it is recognized that various forms of the subject outdoor/indoor bamboo rug could be utilized without departing from the spirit and scope of the present invention.
As is evident from the foregoing description, certain aspects of the present invention are not limited by the particular details of the examples illustrated herein, and it is therefore contemplated that other modifications and applications, or equivalents thereof, will occur to those skilled in the art. It is accordingly intended that the claims shall cover all such modifications and applications that do not depart from the sprit and scope of the present invention.
Other aspects, objects and advantages of the present invention can be obtained from a study of the drawings, the disclosure and the appended claims. | A bamboo Indoor/Outdoor Area Rug that is manufactured from 100% Anji Mountain bamboo from China. The bamboo is all treated with various protective coatings to add resistance to natural factors including water, sun and dirt. All bamboo rugs manufactured for outdoor/indoor use are made from the harder portions of the bamboo trunk. (Some bamboo used for indoor purposes only are manufactured from the softer fibers of the inside of the bamboo trunk). This portion of the bamboo trunk is not utilized for this invention. The bamboo utilized in the present invention is taken from the harder part of the bamboo trunk to assure maximum endurance and longevity. The lower trunk portion of the bamboo plant is harder and less porous. | 8 |
CROSS-REFERENCE TO RELATED PATENT APPLICATION
[0001] This application claims priority to and the benefit of Korean Patent Application No. 10-2011-0127256, filed on Nov. 30, 2011, in the Korean Intellectual Property Office, the disclosure of which is incorporated herein in its entirety by reference.
BACKGROUND
[0002] 1. Field
[0003] The following description relates to a tray for supporting a flat display panel.
[0004] 2. Description of the Related Art
[0005] In general, during manufacturing of a flat display panel, such as an organic light-emitting diode (OLED) panel or a liquid crystal panel, there is a need to perform an examination for examining whether the flat display panel has a defect.
[0006] So far, a flat display panel has been transferred without using additional protective equipment during the examination. However, the flat display panel is often damaged during transfer of the flat display panel. Recently, as flat display panels have become large, a flat display panel may more likely to be damaged when being transferred. In particular, since an OLED panel does not include a backlight unit, such as a liquid crystal panel, the OLED panel has relatively low rigidity, and thus, the OLED panel may be easily damaged when being transferred.
[0007] Accordingly, there is a need to develop a method of easily transferring and examining a flat display panel.
SUMMARY
[0008] An aspect of an embodiment of the present invention is directed toward a tray that enables a user to safely and effectively handle a flat display panel.
[0009] An aspect of an embodiment of the present invention is directed toward a tray capable of being effectively used to safely transport the flat display panel during handling.
[0010] According to an embodiment of the present invention, there is provided a tray for a flat display panel, the tray including: a frame including a seating portion on which the flat display panel sits; a clamping device for clamping the panel so as not to be separated from the seating portion; and a size adjusting device for adjusting a size of the frame to correspond to a size of the flat display panel.
[0011] The clamping device may include: a push lever that is rotatably installed on the frame; and a spring for providing elastic force so that the push lever presses the panel in a direction of the seating portion.
[0012] The clamping device may include: a pair of rotational blocks that are rotatably installed on the frame; a push bar connected to the rotational blocks; and a plurality of fixing fins for respectively fixing the rotational blocks when the panel is pressed in a direction of the seating portion and when the pressing of the panel is released.
[0013] The clamping device may include: a plurality of belts installed on the frame; and a fastening device for connecting the belts to the panel on a side of the panel facing oppositely away from the seating portion so that the fastening device is tightly held (adhered) to the panel.
[0014] A plurality of bumping members may be each installed at a contact portion between an edge portion of the panel and the frame.
[0015] The bumping member may include at least one selected from the group consisting of urethane and silicon.
[0016] The frame may include a plurality of pieces that connect to one another, wherein the size adjusting device may include: a plurality of slide bars that connect the pieces to allow the pieces to approach one another or to move away from one another; and a fastening device for fixing the pieces to the slide bars.
[0017] The fastening device may have a plurality of fastener holes formed in the pieces and a plurality of fasteners for inserting into the fastener holes to be compressed against and fastened with the slide bars.
[0018] A plurality of transferring rollers may be installed on at least one surface of the frame to move along a transfer rail.
[0019] A plurality of slide guides may be installed on a surface facing the transferring rollers of the frame to be slidably coupled to the transfer rail.
[0020] A connecting portion may be installed in the frame to be electrically coupled to the panel.
[0021] The tray may further include a plurality of handles on the frame.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] The above and other features and principles of the present invention will become more apparent by describing in detail exemplary embodiments thereof with reference to the attached drawings in which:
[0023] FIG. 1 is a perspective view of a tray for a flat display panel according to an embodiment of the present invention;
[0024] FIG. 2 is an enlarged perspective view of a clamping device included in the tray shown in FIG. 1 ;
[0025] FIG. 3 is an enlarged perspective view of a size adjusting device included in the tray shown in FIG. 1 ;
[0026] FIG. 4 is a view showing a process of changing a size of a frame by using the size adjusting device shown in FIG. 3 ;
[0027] FIG. 5 is a view showing the tray of FIG. 1 that is used by a user;
[0028] FIG. 6 is a perspective view of a tray for a flat display panel according to another embodiment of the present invention;
[0029] FIGS. 7A and 7B show operations of a clamping device of the tray shown in FIG. 6 ;
[0030] FIG. 8 is a perspective view of a tray for a flat display panel according to another embodiment of the present invention;
[0031] FIGS. 9A and 9B are perspective views of a tray for a flat display panel according to another embodiment of the present invention; and
[0032] FIG. 10 is a perspective view of a tray for a flat display panel according to another embodiment of the present invention.
DETAILED DESCRIPTION
[0033] Now, an exemplary embodiment according to the present invention will be described in detail with reference to the accompanying drawings. Expressions such as “at least one of,” when preceding a list of elements, modify the entire list of elements and do not modify the individual elements of the list.
[0034] FIG. 1 is a perspective view of a tray for a flat display panel according to an embodiment of the present invention.
[0035] Referring to FIG. 1 , the tray includes a frame 100 including a seating portion 110 on which a panel 10 is seated, a plurality of clamping devices 200 for clamping the panel 10 so as not to be separated from the seating portion 110 , and a size adjusting device 300 for adjusting a size of the frame 100 to correspond to a size of the panel 10 .
[0036] First, the frame 100 forms an outer frame for supporting the panel 10 and has a structure in which a plurality of pieces 101 , 102 , 103 , 104 , and 105 are connected to one another. As such, the frame 100 is formed of the plurality of pieces 101 , 102 , 103 , 104 , and 105 to adjust a size of the frame 100 by using the size adjusting device 300 , which will be described below. An edge of the panel 10 is seated on and supported by the seating portion 110 disposed at an inner side of the frame 100 .
[0037] The clamping devices 200 clamp the panel 10 seated on the seating portion 110 so that the panel 10 is not separated from the seating portion 110 . As shown in FIG. 2 , the clamping devices 200 include a push lever 210 that is rotatably disposed on a supporting block 230 formed on the frame 100 and a spring 220 for providing elastic force so that the push lever 210 presses the panel 10 in a direction of the seating portion 110 . Accordingly, after seating the panel 10 on the seating portion 110 and then rotating the push lever 210 , the push lever 210 presses the panel 10 toward the seating portion 110 by elastic force of the spring 220 , thereby preventing the panel 10 from being separated from the seating portion 110 . The clamping devices 200 are installed at a plurality of locations to secure or prevent the panel 10 from being separated from the seating portion 110 . A range within which elastic force of the spring 220 acts may be designed in such a way that the push lever 210 stops when standing perpendicularly with respect to the frame 100 or that the push lever 210 falls to the opposite side at a moment when the push lever 210 exceeds a perpendicularly standing state to be tightly held (adhered) to the frame 100 , like a toggle switch. In other words, if the push lever 210 may safely press the panel 10 disposed on the seating portion 110 , a range within which the push lever 210 rotates may be changed freely. Reference numeral 211 denotes a pressing member contacting the panel 10 , and the pressing member 211 may be formed of a flexible material, e.g., rubber.
[0038] Next, the size adjusting device 300 , as shown in FIG. 3 , includes a plurality of slide bars 310 that slidably connect the pieces 101 to 105 of the frame 100 to one another and a plurality of fasteners 320 that are compressed against the slide bars 310 via a plurality of fastener holes 100 a formed in the pieces 101 to 105 to be fastened with the slide bars 310 . In other words, an entire size of the frame 100 is adjusted by allowing the pieces 101 to 105 to approach one another or to move away from one another based on the slide bars 310 , and in this state, the fasteners 320 are fastened in the fastener holes 100 a to be fixed. Accordingly, the fasteners 320 may be loosened to gather the pieces 101 to 105 along the slide bars 310 and then to assemble the pieces 101 to 105 so that the frame 100 having a large size, as shown in an upper drawing of FIG. 4 , may be changed to the frame 100 having a small size as shown in a lower drawing of FIG. 4 . The upper drawing of FIG. 4 shows a maximum size of the frame 100 , and the lower drawing of FIG. 4 shows a minimum size of the frame 100 . The size of the frame 100 may be adjusted to correspond to various suitable sizes of the panel 10 , by using the size adjusting device 300 within the maximum and minimum sizes of the frame 100 .
[0039] The tray may be effectively used during an examination of the panel 10 , as shown in FIG. 5 . In other words, the panel 10 is seated on and tightly clamped to the frame 100 of which the size is adjusted to correspond to the size of the panel 10 , and then the panel 10 seated on the frame 100 is moved along a transfer rail 20 used during the examination of the panel 10 , and thus, a worker 1 may perform the examination. Accordingly, an OLED panel that has relatively low rigidity compared to a liquid crystal panel may be stably supported by the tray and transferred, thereby protecting the panel 10 from being damaged. Reference numeral 120 that has not been described with reference to FIG. 1 denotes a connecting portion that is electrically coupled to the panel 10 seated on the frame 100 . In other words, the panel 10 seated on the frame 100 and the connecting portion 120 are electrically coupled to each other in the frame 100 , and a signal line is connected to the connecting portion 120 during the examination of the panel 10 to examine a state of the panel 10 . Consequently, the panel 10 may be safely handled by using the tray of the current embodiment, the panel 10 may be conveniently and rapidly examined by using the connecting portion 120 , and the worker 1 may freely see front and rear surfaces of the panel 10 on the transfer rail 20 . Accordingly, the examination may be effectively performed.
[0040] Hereinafter, modified embodiments of the tray according to the above-described embodiment will be described.
[0041] FIG. 6 is a perspective view of a tray for a flat display panel, according to another embodiment of the present invention. The tray of the current embodiment includes the frame 100 , the size adjusting devices 300 , as described above, and a plurality of clamping devices 500 . Accordingly, a size of the frame 100 is adjusted to correspond to a size of the panel 10 by using the size adjusting devices 300 , the panel 10 is seated on the frame 100 , and the panel 10 is tightly clamped to the frame 100 by using the clamping devices 500 , and thus an examination of the panel 10 is performed.
[0042] However, in the current embodiment, the clamping devices 500 are differently configured from the clamping devices 200 of the above-described embodiment. That is, in the above-described embodiment, the push lever 210 presses the panel 10 to fix the panel 10 , while in the current embodiment, a push bar 510 having a long bar shape presses the panel 10 to fix the panel 10 . FIGS. 7A and 7B show a structure and operations of the clamping device 500 . Referring to FIGS. 7A and 7B , a pair of rotational blocks 520 are rotatably formed on the frame 100 , and the push bar 510 is connected to the rotational blocks 520 . Accordingly, as shown in FIG. 7A , the panel 10 is seated on a seating portion 110 when the push bar 510 is raised, and then if the rotational blocks 520 are rotated as shown in FIG. 7B , the push bar 510 presses the panel 10 to be fixed onto the seating portion 110 . In this instance, since the push bar 510 should not be freely moved in an unlocked state, as shown in FIG. 7A , or in a locked state, as shown in FIG. 7B , a plurality of fixing fins 530 are inserted into the rotational blocks 520 via a plurality of fixing blocks 540 , respectively, to fix the push bar 510 . Accordingly, the tray of the current embodiment provides a structure in which the panel 10 may be safely and tightly supported.
[0043] Next, FIG. 8 is a perspective view of a tray for a flat display panel, according to another embodiment of the present invention. A clamping device 600 of the current embodiment is differently configured from those of the above-described embodiments. In other words, in the current embodiment, a plurality of belts 612 are fastened using a fastening device 620 to fix the panel 10 instead of pressing the panel 10 by using the push lever 210 or the push bar 510 to fix the panel 10 . That is, the belts 612 installed in the frame 100 are connected to each other via the fastening device 620 to be tightly held (adhered) to the panel 10 on a side of the panel 10 facing opposite away from the seating portion 110 . Thus, the panel 10 is bound by the belts 612 to be supported by the belts 612 so as not to be separated from the seating portion 110 . Accordingly, the panel 10 may be supported by using not only a push member, but also the belts 612 .
[0044] Next, FIGS. 9A and 9B are perspective views of a tray for a flat display panel, according to another embodiment of the present invention. The current embodiment exemplifies a structure in which the tray may be easily moved along the transfer rail 20 (see FIG. 5 ). In other words, FIG. 9A shows an upper surface of the frame 100 and FIG. 9B shows a lower surface of the frame 100 . As shown in FIG. 9B , a plurality of transferring rollers 720 are installed on the lower surface of the frame 100 to move along the transfer rail 20 . A plurality of slide guides 710 are installed on the upper surface opposite to the lower surface of the frame 100 , as shown in FIG. 9A . Accordingly, if the transfer rail 20 is formed to match with the slide guides 710 and the transferring rollers 720 , the panel 10 may be smoothly moved to be examined by using the tray of the current embodiment.
[0045] FIG. 10 is a perspective view of a tray for a flat display panel, according to another embodiment of the present invention. The tray of the current embodiment has a structure in which a plurality of bumping members 800 are installed in the seating portion 110 of the frame 100 . In other words, an edge portion of the panel 10 contacts the frame 100 , and the edge portion of the panel 10 may often collide with the frame 100 during handling of the tray, and thus, a contact portion between the edge portion of the panel 10 and the frame 100 may be damaged. Accordingly, the bumping members 800 may be installed on the contact portion to cushion the impact. The bumping members 800 may be formed of urethane or silicon. Thus, according to the current embodiment, the panel 10 may be safely supported to prevent damage due to impact.
[0046] A plurality of handles 400 may be installed on all the above-described frames 100 , as shown in FIG. 1 , to facilitate handling of the trays.
[0047] While the present invention has 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 invention as defined by the following claims, and equivalents thereof. | A tray for a flat display panel. The tray includes a frame including a seating portion on which the flat display panel sits; a clamping device for clamping the panel so as not to be separated from the seating portion; and a size adjusting device for adjusting a size of the frame to correspond to a size of the panel. The tray allows the frame to be safely and firmly supported and transported, thereby greatly preventing the panel from being damaged during an examination of the panel and improving efficiency of the examination. | 1 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part and claims the benefit under 35 U.S.C. §120 of U.S. application Ser. No. 10/680,377 filed Oct. 7, 2003 and U.S. application Ser. No. 10/708,571 filed Mar. 11, 2004, and 35 U.S.C. § 119(e) of U.S. Provisional Application Ser. No. 60/417,257 filed Oct. 9, 2002, hereby specifically incorporated by reference in their entirety.
BACKGROUND OF THE INVENTION
[0002] This invention relates to nondestructive detection of termite infestation in a structure and, more particularly, to methods for detecting and preventing termite damage.
SUMMARY OF THE INVENTION
[0003] Termites are extremely destructive to wood material. Termites attack and destroy wood almost everywhere in the world, with the exception of climate zones that experience hard freezing. There are close to fifty species of termites in the United States, the majority of losses to wood material being caused by subterranean species. All termites are social insects. They live in colonies that can number over one million individuals.
[0004] It is difficult to put a dollar amount estimate on termite damage. However, renowned termite scientist Dr. Nan Yao Su at the University of Florida has estimated that the total annual cost of termite control and damage repair for the United States alone was $11 billion in 1999.
[0005] Few homes are treated for termite detection/prevention during construction, although this is the best and most economical way to prevent termite attack. Untreated foundations make the house very susceptible to termite attack. It is often very difficult and costly to apply effective control measures after a building has become infested with termites.
[0006] It is rarely apparent from visual observation that a termite infestation is active and that wood damage is occurring. Typically, only about 30 percent of structural wood in a structure is visible for visual inspection. Even when visible wood is to be inspected, an inspector often has to rely on secondary signs of an infestation, such as moisture staining, the presence of foraging tubes and debris expelled from termite colonies.
[0007] Another method often used to detect termites is to tap the surface of the wood while listening for a characteristic sound indicative of an underlying gallery void. When a suspected area is located, the inspector applies a sharp probe, such as a screwdriver, to break the wood surface and locate wood galleries and live termites. This method has significant disadvantages. The confirmation of an active infestation requires some localized damage to the wood. Also, when termites are exposed in this manner, the destruction induces termites to retreat from the disturbed area and may reduce the effectiveness of a subsequent localized treatment.
[0008] Commercial demand for a dependable, nondestructive and nonsubjective method to detect termites has spawned a number of alternatives to visual inspection. However, none of these techniques has satisfied the non-destructive and non-subjective requirements, and many infestations are still missed.
[0009] Prior devices for nondestructive detection of termites may be generally classified into four categories: (1) Apparatus having sensors that detect the presence of gases emitted by termites, as disclosed for example in U.S. Pat. No. 6,150,944; (2) Apparatus having acoustic sensors that detect insect sounds at high or ultrasonic frequencies, as disclosed for example in U.S. Pat. No. 4,809,554 to Shade et al., U.S. Pat. No. 5,285,688 to Robbins et al., and Japanese Patent Application JP H07-143837; (3) Apparatus having sensors that detect destruction of a baited sample, for example, inclusion of circuit elements designed to be destroyed as the sample is destroyed, thereby breaking a circuit, as disclosed in U.S. Pat. Nos. 6,052,066; 5,815,090; 5,592,774; activation of a switch by movement of a mechanical element in response to sample destruction, as disclosed in U.S. Pat. No. 5,571,967 and Japanese Patent Publication No. H7-255344; or penetration of a film across the entrance to a baited trap, as disclosed in U.S. Pat. No. 5,877,422; and (4) Apparatus employing infrared sensors.
[0010] Detection devices that rely on sensing the presence of termite-created gases eliminate the need to use bait to attract the termites, and, in theory, they can signal the actual locations of the termites. A significant disadvantage, however, is that the gases must be abstracted within a confined space, such as within the walls of a structure. These devices are thus unsuitable for detecting termites in wood that is not within a confined space. Moreover, the use of these devices to detect termites is very time-consuming and costly as a result.
[0011] Detection devises that rely on sensing ultrasonic termite sounds, on the other hand, offer the advantage that they can be placed on the exterior of structural walls rather than within the walls. The ultrasonic frequencies, however, are difficult to detect through walls and other concealing structures due to the signal's very short distance of travel (ultrasonic frequencies have very high transmission loss), and this process fails to take into account the full range of termites noises, which fall primarily in the range of 100 Hz to 15 kHz.
[0012] An alternative to devices employing ultrasonic acoustic sensors is a device employing sensor (or electronic stethoscope) arranged to detect acoustic signals and process them for listening and directs interpretation by a trained operator. In some cases, the device may be connected to a spectrum analyzer arranged to generate a plot of signals in the frequency domain, which can then be interpreted by the operator. These devices require a high degree of operator skill. In addition, such devices typically use a relatively narrow frequency range. For example, the device disclosed in U.S. Pat. No. 4,895,025 is focused on a frequency range of 1462.5 Hz to 3337.5 Hz. The device of U.S. Pat. No. 4,941,356 (the '356 patent), on the other hand, is evidently intended to work over a broad range of audible frequencies (100 Hz to 15 kHz). The '356 patent, however, fails to disclose specific apparatus, algorithms or noise patterns useful for detection over the specified frequency range.
[0013] The various devices for sensing the destruction of bait sample are useful for detecting the presence of termites in the vicinity of a structure, but cannot be used to locate precise areas of termite infestation in concealed areas within the structure. Once it has been determined that termites are present in the vicinity of the structure, the only way to determine the actual locations of termites within the structure is to remove portions of the structure, which is, again, damaging and costly.
[0014] It has also been proposed to use infrared sensors to detect the surface temperature differences indicative of termite infestations. Infrared detection works because subterranean termites require a high percentage of humidity in their living environment. Moisture brought in by the termites produce a temperature change in the wall, which can be detected by an infrared thermal imaging device. However, this is a relatively nonspecific method, yielding many, many false positives since there are many sources of temperature differences in a typical structure, such as non-uniform insulation material, air-conditioning ducts, leakage, air movement through wall cracks, water and moisture problems, etc. As a result, detection of termites using infrared sensors still requires destruction of walls to verify results and to more specifically locate the actual termite infestations. Furthermore, use of infrared sensing for detection of termites also requires a relatively high degree of operator skill, training and judgment which adds time and cost to its use.
[0015] Devices relying on acoustic detection appear to offer the best combination of accuracy and lack of destruction. Such devices, however, generally do not take into account the full range of termite sounds, as explained above. Moreover, the design of prior devices has generally resulted in only highly localized detection ability, thereby necessitating the taking of many samples or data points, and requiring an inordinate amount of time or number of sensors to completely inspect a structure.
[0016] As a result of the various practical difficulties outlined above, the prior devices described above have generally seen insignificant commercial implementation despite the long-felt need for nondestructive termite and wood-destroying insect detection. There is still a need for a nondestructive, reliable and easy-to-use apparatus and method for detecting termites.
[0017] The present invention relates to a method to detect termite infestation. In particular, an infrared scan of a structure is conducted to identify potential infestation sites. Then once potential infestation sites are identified, another nondestructive detection method such as a microwave is used to confirm termite infestation in the structure.
[0018] Preliminary infrared detection has the advantage of covering a much larger area than acoustic detection and, although less specific or accurate than acoustic detection, provides efficient screening and a convenient way of scanning the structure for potential infestations in order to guide placement of detectors in order to carry out more specific tests. In this way, inspection time requirements, and, therefore, costs, are greatly reduced. Further, detection accuracy is greatly increased. The combination of infrared and other detection method couples a quicker but low-specificity screening technique for speed with a high-specificity, slower technique for accuracy and is a significant improvement in the art having important commercial applications.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1 is a schematic illustration of a termite detection system assembled in accordance with the principles of a preferred embodiment of the invention.
[0020] FIG. 2A is an infrared scan of a structure showing drywood termite infestation.
[0021] FIG. 2B is a photo of a wood structure with the surface material removed.
[0022] FIG. 3A is an infrared scan of a structure showing drywood termite infestation.
[0023] FIG. 3B is a photo of a wood structure with the surface material removed.
[0024] FIG. 4A is a photograph of a wall.
[0025] FIG. 4B is an infrared scan of the wall.
[0026] FIG. 4C is a photograph of the wall with the dry wall removed, it shows the2×4 stud damaged by subterrarean termite.
DETAILED DESCRIPTION
[0027] As schematically depicted in FIG. 1 , a preferred embodiment of the apparatus and method of the present invention includes a thermal imaging camera 1 for performing a preliminary scan of a structure 13 in order to locate potential termite infestations sites 3 . A thermal imaging camera 1 is used to perform an infrared scan. The structure 13 can be a wooden object, such as a wall stud, paneling or in one embodiment a live tree. Termite infestation sites 3 can be the result of subterranean termite or dry-wood termite activity. In the case of a subterranean termite infestation, the moisture brought in by the subterranean termites will show up as a “suspicious cold or hot spot” in a thermal imaging scan. In the case of a dry-wood termite infestation, a heat or cold source 9 is needed to increase or decrease the temperature of a targeted structure 13 . This heat source 9 can be an electric, gas or oil heat source as well as an incandescent or infrared light source. The areas in the targeted structure 13 that contain a cavity created by dry-wood termites will show up as “suspicious warm or hot spots.” The correspondent video images of the potential termite infestation are recorded by the camcorder 2 or by the thermal imaging camera if it is equipped with recording capability 6 .
[0028] Thermal imaging camera 1 may be any of a number known, commercially available infrared cameras conventionally used by structural engineers, police and the military. In order to improve the accuracy by which the thermal imaging camera 1 detects potential areas of termite infestation, the thermal imaging camera may further include termite infestation recognition software, such as matched filtering software which compares the frequency spectrum of a thermal image with frequency spectra of a reference images known to indicate termite infestation, thereby reducing the level of skill required of the camera operator, reducing time required and increasing termite identification effectiveness. This database of infestation images of suspicious thermal images can be built by one skilled in the art.
[0029] Specific equipment to facilitate an infrared scan of a structure and procedures to enhance the resolution of the scan are described in U.S. patent application Ser. No 10/708,571.
[0030] Referring now to FIGS. 2A and 2B , an infrared scan of a wall shows potential termite damage at 50 , 51 and 52 . The surface material was removed in FIG. 2B to show termite damage at 53 , 54 and 55 .
[0031] Referring now to FIGS. 3A and 3B , an infrared scan of a wall shows potential drywood termite damage at 61 - 67 . The surface material was removed in FIG. 2B to show termite damage at 70 - 76 .
[0032] FIG. 4A 4 C show additional preliminary infrared detection. In FIG. 4A , a photograph of a wall is shown. This is what a human eye sees. In FIG. 4B , a preliminary infrared scan shows suspicious black spots which might be subterranean termite infestation. Subterranean termite infested areas contain very high moisture content, as the moisture evaporates infested areas appear as cold spots. In FIG. 4B , when the wall is removed, actual termite damage is shown at 60 and 61 . However, it would be better to confirm wood damaging termite damage or infestation prior to destructive of the dry wall.
[0033] More specifically, upon a preliminary thermal indication of termite infestation observed with thermal imaging camera 1 , detectors are positioned on the wall of the structure adjacent to the potentially infested locations in the structure 13 . The detectors can be used to confirm termite infestation. These detectors include but are not limited to microwave motion detector, dogs, sound (acoustic), fiber optic scope, and gas detection and x-ray detection. A microwave motion detector can detect termite movement inside the wall cavity, however, the operator must be perfectly still while holding the device. Very often high moisture content in the wall cavity prevents an accurate measurement. Moisture content; however, can be differentiated through infrared detection. U.S. Forest Service, Mississippi. Additionally, dogs are now being used by some pest control specialists in the detection of termites. The handler/inspector is a key part of this inspection team. This individual should be a well-trained termite inspector, and also someone who can properly handle and care for the dog and become familiar with the cues and responses the dog gives when it detects an insect infestation. Truman's Scientific Guide to Pest Control Operations, 5 th Edition. Gas detectors have been marketed to aid in termite inspections. Id. X-ray detection is one of the latest pinpoint inspection techniques. X-ray detection produces a good image of termite infestation in wood structure. However, this technique requires a radioactive source and can only be employed under very strict conditions in order to contain radio active radiation. This is an active device and requires FDA and EPA approval. In addition, the equipment is quite expensive and requires extensive training.
[0034] Although the foregoing invention has been described in some detail by way of illustration and example for purposes of clarity of understanding, it will be obvious that certain changes and modifications can be made which are within the full scope of the invention. | A method for confirming the presence of termites in a structure, involving a preliminary infrared scan of a structure and confirmation of termite infestation with at least one detector in order to quickly locate potential areas of termite infestation. | 6 |
BACKGROUND OF INVENTION
The present invention relates to a temperature-compensating clock pulse generating circuit which generates temperature compensating clock pulses having a deviation of period within several tenth ppm. in a wide temperature range between, for instance, -50° C. and 100° C.
The temperature compensating circuit is effective especially for a timepiece. Recently, an accuracy of a timepiece has been improved since a quartz crystal has been brought into use for a resonator, and the allowable range of error to prove the accuracy of the timepiece has been expressed as a monthly error and further it has been shifted to be expressed as an annual error. However, the timepiece which displays the time accurately to this extent has not been realized by a single quartz crystal resonator which is generally used at present. Accordingly, a wrist watch which displays time accurately by employing two resonators has been put into a practical use by the following two methods. (These methods are illustrated in detail in 9-18 issues, 1978 and 2-19 issues, 1979 of the "Nikkei Electronics") One method is to use two quartz crystal resonators A and B (referred to resonator hereafter) having negative secondary temperature coefficients. The secondary temperature coefficients of the resonators A and B are the same, the peak temperature of the resonator A is higher than B, and frequency at the peak temperature of A is lower than B. The characteristics of the two resonators A and B are set in order that the temperature characteristic of the resonator B at the high temperature side coincides with the peak frequency of the resonator B at the peak temperature of A. And beats of the resonators A and B having the characteristics correlated as illustrated above are extracted to produce various temperature compensating pulses in an electronic circuit on the basis of the beats, and a constant period pulse against time is extracted by inserting the compensating pulse.
The other method is the conventional method in which two X-cut resonators having the same temperature characteristics and different peak temperatures are connected in parallel to act as one quartz crystal resonator equivalently.
Both the two methods have the disadvantages in common. Namely, it is difficult to set the characteristics of the resonators act as one couple, i.e., it is necessary to further select a couple of resonators of within a certain tolerance. Therefore, the resonators, which in the nature of things, could have been housed in one case, cannot but housed separately. Moreover, the temperature range to be compensated, using a couple of resonators, is no more than around between 0° and 50°, and this temperature compensating range is insufficient to assure the accuracy of the timepiece to the extent of the annual error of the time display under any areas and any circumstances.
BRIEF SUMMARY OF INVENTION
Accordingly, it is an object of the present invention to eliminate the above illustrated major disadvantages and to provide a temperature compensating circuit which can utilize not only the resonators having strictly limited feature but also the resonators having the other characteristics.
Other and further objects, features and advantages of the invention will appear more fully from the following description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fundamental circuit block according to the present invention,
FIG. 2 is a time chart of the major signals in FIG. 1,
FIG. 3 is an embodiment of the operation circuit, the comparator and the counter,
FIG. 4 is an embodiment of the gate time setting circuit in FIG. 1,
FIG. 5 shows time charts of FIG. 4,
FIG. 6 is a characteristic diagram of TvsN, f 1 T and f 2 T,
FIG. 7 is a characteristic diagram of NvsT and f 1 T,
FIG. 8 is a frequency-temperature characteristic obtained by the present method,
FIG. 9 is a diagram showing the relation between the fundamental frequency and the temperature characteristic in case the fraction of figures are cut off,
FIG. 10 is a diagram showing the relation between the fundamental frequency of the temperature characteristic in case the fraction of figures are rounded to the nearest whole number, and
FIG. 11 is a diagram showing the frequency variation by varying the counting value of the fundamental frequency.
DETAILED DESCRIPTION OF THE INVENTION
Referring first to FIG. 1, there is shown a fundamental circuit block which achieves the object of the present invention, in which resonators 1 and 2 are housed in the same case 3 in order to improve a thermal coupling. The resonator 1 is a major resonator and the resonator 2 is a subsidiary resonator. Both the resonators 1 and 2 have the negative secondary temperature coefficients. The temperature coefficient of the resonator 2 is larger than the resonator 1, the peak temperature of the resonator 2 is lower than the room temperature and the frequency of the resonator 2 at the peak temperature is higher than that of the resonator 1. The peak temperature of the resonator 1 is near the room temperature. The X-cut resonator of 32 KHz is sufficient for the resonator 1. It is possible for the X-cut resonator presently disclosed and the other resonators to change the characteristics in accordance with the course as illustrated above, i.e., to increase the temperature coefficients and to reduce the peak temperatures. But it is very difficult to change the characteristics reversely, i.e., to decrease the temperature coefficients and to raise the peak temperature. Oscillators 4 and 5 respectively oscillate the resonator 1 and the resonator 2. The output from the resonator 2 is fed to a gate time setting circuit 6, and the output from the resonator 1 is counted by a counter 7 at a gate time produced by the gate time setting circuit 6, and the counting value is N. The gate time set by the gate time setting circuit 6 is a time necessary to count k pieces of output pulses of the resonator 2. The concrete circuit structure of the gate time setting circuit will be illustrated later.
Now the significance of the counting value N with respect to temperature will be illustrated. Arbitrary temperature of the resonators 1 and 2 is T, oscillating frequencies at the arbitrary temperature are respectively f 1 T and f 2 T, peak temperatures are respectively T 1 and T 2 , secondary temperature coefficients β 1 and β 2 , and tertiary temperature coefficients are α 1 and α 2 in FIG. 1. If the gate time obtained by the gate time setting circuit 6 is the time taken to count K pieces of the outputs from the resonator 2, the counting value N is represented by the following formula. ##EQU1##
Namely N is a function with respect to the characteristics of the resonators 1 and 2 and the temperature T. The formula (1) is further developed to kf 1 T-Nf 2 T=0 . . . (2). And if an equation is set up with respect to T, AT 3 +BT 2 +CT+D=0 . . . (3), where A=kf 1 α 1 -Nf 2 α 2 , B=kf 1 (β 1 -3α 1 T 1 )-Nf 2 (β 2 -3α 2 T 2 ), C=kf 1 (3α 1 T 1 2 -2β 1 T 1 )-Nf 2 (3α 2 T 2 2 -2β 2 T 2 ) and D=kf 1 (β 1 T 1 2 -α 1 T 1 3 +1)-Nf 2 (β 2 T 2 2 -α 2 T 2 3 +1). The values of A to D inclusive are determined by measuring the counting value N since the value varied according to the temperature T is only N. Therefore the value of T is found by expanding the equation (3), and f 1 T is determined by substituting the value of T for f 1 T=f 1 {1+β 1 (T-T 1 ) 2 +α 1 (T-T 1 ) 3 }. . . (4). Though f 1 T at an arbitrary temperature T is determined by adopting the regular method there is a problem for operating the root of a cubic equation T by an IC within a watch body since the area of IC enlarges and the power consumption increases. Therefore the method to find f 1 T from the counting value N without finding the temperature T will be illustrated later. But the description will be continued on the assumption that f 1 T have been found, temporarily. f 1 T is found by an operation circuit 8 by the method mentioned later, and the value f 1 T is maintained for a fixed period as the counting output. A counter 10 keeps counting receiving the oscillating frequency f 1 T of the resonator 1 as an output. The oscillating frequency f 1 T varies subjected to the temperature variation. The counted output connected by the counter 10 is compared with the counted output from the operation circuit 8 digitally by a comparator 9 for a fixed period of time. The comparator 9 produces the output to reset the counter 10 when both the counted outputs coincide. The reset counter 10 counts the oscillating output f 1 T of the resonator 1 newly and repeats the same operation hereafter. Temperature of the output period T of the counter 10 synchronized with the reset signal produced from the comparator 9 is compensated and becomes a fixed period against time.
The principal mentioned above can be summarized as follows. The one output period of the counter is always fixed regardless of temperature by counting the number of pulses per a unit time varied by temperature because the capacity of the counter is changed corresponding to the temperature.
Subsequently the time relation of each major signal in FIG. 1 will be illustrated by the time chart in FIG. 2. Each signal (a) to (e) inclusive in the time chart in FIG. 2 is the signal corresponding to (a) to (e) inclusive in FIG. 1, but (f) and (g) are not shown in FIG. 1. FIG. 2 shows each signal under the normal condition of the circuits in FIG. 1, and the circuit operation at start will be illustrated later. Duty cycles of pulses of each signal (a), (c), and (e) in FIG. 2 are drawn correctly for convenience of the drawing. The signals (a) and (c) in FIG. 2 are the outputs (a) and (c) of a couple of resonators in FIG. 1, both of which vary momentarily subjected to the temperature variation. The signal (b) in FIG. 2 is a period T(b) of the counter 10 in FIG. 1, the temperature of which is compensated, obtained by the method mentioned before. The signal (d) in FIG. 2 is the gate time (d) made in the gate time setting circuit 6 in FIG. 1, which is obtained by the following method.
The signal (c) in FIG. 2 is started counting just after the temperature-compensated period T(b) produced from the counter 10 in FIG. 1, and the time corresponding to k pulses of the predetermined signal (c) is the gate time (d). A counting value N(e) in FIG. 2 is obtained by counting the signal (a) by the counter 7 in FIG. 1 during the gate time (d). The counting value N(e) is transmitted to the operation circuit 8 by the required number of bits, and the time taken to operate the required content by the operation circuit 8 is shown by the positive pulse width of the signal (f) in FIG. 2. The positive pulse width of the signal (g) in FIG. 2 indicates a wait time from the time the operation of the operation circuit 8 is over and the counting value is produced by the necessary number of bits until the counting value coincides with the counting value of the counter 10.
Take note that it is not necessary to produce the counting value of the operation circuit 8 constantly during the time interval between the previous coincidence of the counting value of the counter 10 in FIG. 1 and the counting value of the operation circuit 8 and the next coincidence thereof. That is to say, the frequency variation range of the resonator 1 in FIG. 1 is no more than several ppm order. Therefore, if the frequency is calculated on trial when the secondary temperature coefficient is -4×10 -8 /°C. estimating highly, (the tertiary temperature coefficient is ignored since it scarcely effects on the frequency), the peak temperature is 25° C. and the frequency at the peak temperature is 32768 Hz, the frequency varying in the range between -50° and 100° C. is in the range between 32761 Hz and 32768 Hz raising to an integer not lower than the decimal point, i.e., the former four figures 3276 are fixed in the above mentioned temperature range. The time taken to count 32768 pulses and the time taken to count 8 pulses are in the ratio 4096:1, the other words, in the ratio 1:0.00024. If it takes one second to count 32768 pulses. 0.3 msec is enough to count 8 pulses. The counting value of the operation circuit 8 and the counting value of the counter 10 coincide in the time interval of 0.3 msec, and the counting output of the operation circuit 8 in FIG. 1 is unnecessary during the former 0.9997 msec.
By the reasons illustrated so far, the short time interval as the signal (g) in FIG. 2 is enough for the counting output of the operation circuit 8 in FIG. 1.
FIG. 3 shows an embodiment of the operation circuit 8, the comparator 9 and the counter 10 surrounded by dotted line in FIG. 1 more concretely, where the numerals corresponding to the numerals in FIG. 1 denote the same portions. AND circuits 13 and 14 are newly added. However, the digital pulse compensating method accompanies error of quantigation represented by 1/f when the frequency is f. If the oscillation frequency of the resonator 1 in FIG. 1 is f=32768 Hz, the resolution is no more than 30 ppm per one pulse. Therefore, in order to satisfy the conditions for practical use, if the temprature is compensated by 256 f, i.e., 8388608 pulses, the resolusion of 0.12 ppm per one pulse is obtained. Namely, if the oscillating frequency of the resonator 1 in FIG. 1 is f=32768 Hz and compared once 256 seconds, the number of pulses vary in 256 seconds as described above are between 8386816 and 8388608, i.e., the number of the fixed pulses are 8388608 and the variable pulses are 1792. If the pulses are converted into bits, the signals corresponding to eight bits vary and the remaining signals corresponding to fifteen bits can be fixed. If this condition is applied to the circuits in FIG. 3, the variable signals corresponding to eight bits are transmitted from the counter 10 to the comparator 9 as shown by the arrows and the fixed signals corresponding to fifteen bits are transmitted from the counter 10 to the AND circuit 13 as shown by the arrows.
All the inputs fed to AND circuit 13 are the positive logic "1" from the nature of things when the fifteen bits signals fed to AND circuit 13 are the fixed value. It is not until the output from the AND circuit 13 is produced that AND condition is set by the output signal from the comparator 9 and AND circuit 14, and the counter 10 is reset by the output from the AND circuit 14 as shown. In this case the counting output of the operation circuit 8 is, of course, not more than eight bits.
While the compensating method of the outputs from the resonator 1 in FIG. 1 is selected according to the object. Namely, the output is compensated each one second period or each n seconds period collectively.
If the method to compensate the output each n second period collectively is selected, the wavelength of the one second outputs of the counter 10 slightly deviate from one second up to (n-1)th pulses influenced by temperature, and the error deviation up to (n-1)th pulses influenced by temperature is compensated collectively at n-th pulse. This method to compensate the output from the resonator 1 n pieces collectively is effective enough since the timepiece is a time integrating instrument.
Subsequently the embodiment of the method to obtain the gate time by the gate time setting circuit 6 in FIG. 1 conceretely and the method to obtain the gate time (d) from the start condition that the period T(b) does not exist in FIG. 2, will be illustrated in conjunction with FIGS. 4 and 5.
The circuits surrounded by a dotted line in FIG. 4 is an embodiment of the gate time setting circuit 6 in FIG. 1, and symbols (a) to (j) inclusive representing each signal correspond to the symbols in FIG. 1 to FIG. 5 inclusive. The gate time setting circuit 6 comprises OR circuit 15, a trigger flipflop 16 (hereinafter referred to T.FF), AND circuit 17 and n-counter 18 and connection of each signal is as shown in FIG. 4.
FIG. 5 shows time charts of each signal (b), (c), (d), (h), (i) and (j) inclusive in FIG. 4. T.FF 16, n-counter 18 in FIG. 4 and all sequential circuits in FIG. 1 are automatically reset for an instant after the power source is applied in order to zero the primary value. And the n-counter 18 is reset by the signal at a low level, and conditions of T.FF 16 and the n-counter 18 change at the positive going waveform. If the power source is applied at t 1 in FIG. 4 and FIG. 5, the power source is automatically reset at t 2 . In this condition only Q signal (d) of T.FF 16 is at a high level and the other signals are at a low level (hereafter a high level and a low level are respectively referred to H and L). The reset condition is removed at t 3 and the resonator output (c) in FIG. 1 is fed at t 4 . (Since t 1 to t 4 inclusive are the operation at start for an instant, the waveforms in FIG. 5 do not correspond to each signal and the waveforms after t 4 correspond to each signal). When the signal (c) is fed to n-counter 18 by way of AND 17, Qk output (h) of n-counter 18 becomes H, an output (i) of OR circuit 15 becomes H, Q-output (d) of T.FF 16 becomes L and an output (j) of AND circuit becomes L by the k-th signal (c) at t 5 , and when n-counter 18 is reset, Qk output (h) and OR circuit output (i) abruptly become L and the wedge pulses are produced.
Thereafter the circuit condition of FIG. 4 cannot be changed except by the period T(b). The (j) output is generated by the signal of period T(b) produced by the counter 7, the operation circuit 8, the comparator 9 and the counter 10 after t 5 as illustrated in FIG. 1. The signal of period T(b) is fed to an input of OR circuit 15 at t 6 and transmitted to the output (i) of OR 15 as it is and reverses the output Q (d) of T.FF 16 and removes a reset of n-counter 18 in FIG. 4, at the same time, the output (c) of the resonator in FIG. 1 is produced as the output (j) of AND circuit 17, and n-counter 18 turns the output (h) of Qk to H at k-th of the signal output (c). Thereafter the same operation is repeated.
The time charts in FIG. 5 shows the operation of the gate time setting circuit 6 in FIG. 4. The gate time obtained by the gate time setting circuit in FIG. 4 is the signal (d) in FIG. 5. The gate time is not constant and varies according to temperature. As illustrated above, the gate time setting circuit operates smoothly from start condition.
Subsequently the aforementioned "predetermined k pulses" will be illustrated. The predetermined k pulses corresponds to k in case n-counter 19 in FIG. 4 is changed to k-counter, and k is the number of the signal (j) in FIG. 5 between t 4 and t 5 . It means that the interval between t 4 and t 5 is the time for sampling the temperature and in order to elongate the time interval, it is necessary to enlarge k. The more k enlarges, the more the number of the signal (j) increases as well as the more the counting value N increases. By an increase in a counting value N, the temperature resolution goes up. The upper limitation of k is determined by the conditions that the interval between t 5 and t 6 should be included in the interval between t 4 and t 6 of the signal (j). The other words, the operation period of the operation circuit 8 in FIG. 1 and the wait period of the signal (g) in FIG. 2 should be included in the interval between t 4 and t 6 of the signal (j). Therefore k corresponding to the remaining time will be selected after the maximum variation range of the signals (f) and (g) in FIG. 2 are decided. Then the method to obtain f 1 T from the counting value N will be illustrated.
FIG. 6 is a characteristic diagram showing the relation between f 1 , f 2 , N and T in case f 1 =32768 (Hz), β 1 =3×10 -8 (°C. 2 ) -1 , α 1 =-1×10 -10 (°C. 3 ) -1 , T 1 =25(°C.), f 2 =33000 (Hz), β 2 =-6×10 -8 (°C. 2 ) -1 , α 2 =-1×10 -10 (°C. 3 ) -1 and k=7800000. FIG. 7 is a characteristic diagram showing the relation between f 1 T, T and N revising the relation of FIG. 6. The relation of f 1 T=F(N) is approximated by developing the formula of Taylor's series. Although the degree of the term to be developed is determined by the requird precision, it is sufficient to develop the formula to the third degree practically. If f 1 T=F(N) is approximated to the third degree of the term, f 1 T=AN 3 +BN 2 +CN+D. Four absolute terms from A to D inclusive are obtained by measuring the values of N and f 1 T by the counter at four arbitrary temperatures.
If the values N and f 1 T at the four arbitrary temperatures Ta, Tb, Tc and Td are respectively Na, Nb, Nc, Nd, f 1 Ta, f 1 Tb, f 1 Tc and f 1 Td, the following biquadratic simultaneous equations of four elements are respresented.
f.sub.1 Ta=N.sup.3 aA+N.sup.2 aB+NaC+D
f.sub.1 Tb=N.sup.3 bA+N.sup.2 bB+NbC+D
f.sub.1 Tc=N.sup.3 cA+N.sup.2 cB+NcC+D
f.sub.1 Td=N.sup.3 dA+N.sup.2 dB+NdC+D
And by developing the following 4 lines and 4 rows, A, B, C and D are obtained. ##EQU2##
If A, B, C and D are determined, f 1 T is determined by f 1 T=AN 3 +BN 2 +CN+D. In order to raise the precision of f 1 T more, it is effective to apply the minimum binary system by multiplying the measuring points. The precision at the arbitrary temperature is not necessary for this measuring method but it is sufficient to fix the arbitrary temperature, and f 1 T of high precision is realized since the measuring value is N and the frequency is f 1 T. To tell more concretely, if f 1 T is approximated by a cubic equation, f 1 T is obtained by f 1 T=AN 3 +BN 2 +CN+D.
FIG. 8 is a frequency-temperature characteristic diagram showing substantially a fixed temperature characteristics in a wide range obtained by the temperature compensating circuit applying the principle of the present method.
Lastly the relation of the frequency tuning will be illustrated. The counting outputs of the operation circuit 8 in FIG. 1 should be integers and fractions should be omitted, raised to a unit or rounded to the nearest whole number. FIGS. 9 and 10 are the correlation diagrams between the fundamental frequency and the temperature characteristics in which fractions are treated differently, where the abscissa shows the ambient temperature, the ordinate shows the amount of deviation from the reference frequency indicated by ppm, c represents a reference frequency, a represents the amount of plus deviation from the reference frequency, b represents the amount of minus deviation from the reference frequency. Both a and b have certain widths in order to show the range of quantigation error. FIG. 9 shows the deviation of the temperature characteristics in case fractions are omitted, in which the amount of plus deviation is larger than the amount of minus deviation. The rate of the plus deviation and the minus deviation is reversed in case fractions are raised to a unit (not shown). FIG. 10 shows the deviation of the temperature characteristic in case fractions are rounded to the nearest whole number. This figure is preferable since the amount of plus deviation and the amount of minus deviation is substantially the same. Then terminals 11 and 12 attached to the operation circuit 8 in FIG. 10 will be illustrated.
As illustrated before, though f 1 T is obtained by f 1 T=AN 3 +BN 2 +CN+D, the f 1 T value may be varied by constructing the circuit so that the D value may change arbitrary by switch operation of the terminals 11 and 12. If the D value enlarges, the reference frequencies of FIG. 11 are changed from a to b and b to c, and the frequency can be adjusted.
As illustrated in detail hereinbefore, by applying the present method, the following advantages are obtained in comparison with the conventional method:
1. The temperature compensating range is wider than the conventional method.
2. Since the degree of the freedom of the characteristics of the two quartz resonator is high, the tuning of the characteristics as a couple is unnecessary, as a result the productivity becomes high.
3. Since all the signals are representated digitally, this method is suitable for applying to an IC.
4. This method can be adopted to various resonators.
Although the embodiments of the present invention applied to the X-cut resonator have been illustrated, it is possible to apply to the other resonator having different characteristics. | Temperature compensating circuit for an electronic timepiece having two piezo electric resonators having different frequency-temperature characteristics.
Two piezo electric resonators are a major resonator having smaller frequency variation rate in temperature variation and a subsidiary resonator having larger frequency variation rate in temperature variation.
And also the temperature compensating circuit includes a variable counter for counting the output signal of the major oscillator having the major resonator, a gate time setting circuit controlled by both the outputs of subsidiary and the variable counter, and a counter for counting the output signal of the major oscillator.
As a result, the temperature compensating circuit is able to improve the accuracy of the timepiece. | 6 |
[0001] This application is a continuation of U.S. patent application Ser. No. 11/230,325, filed Sep. 19, 2005, which claims the priority benefit of U.S. Provisional Application No. 60/611,563, filed Sep. 20, 2004, the disclosures of which are incorporated herein by reference in their entireties.
TECHNICAL FIELD
[0002] This invention relates to methods implemented by policy servers on a network such as a cable, DSL, FTTx, xPON, 3G (wireless) networks.
BACKGROUND OF THE INVENTION
[0003] Currently allocation of resources in networks such as cable networks is typically done on a best efforts basis, i.e., the subscribers compete with all other devices on an equal basis. The systems do not commit resources to end-points, rather all end-points compete to get a share of the same resources. So, subscribers end up using whatever they get. In many existing systems, the applications have been designed or modified on the assumption that the best efforts approach will be used, i.e., they have been designed or modified to account for known shortcomings of the best efforts approach. Thus, if there are three end-points (A, B, and C) that will be participating in a session after each has obtained whatever resources it is able to obtain on the best efforts basis, they will negotiate to determine which has the best upstream/downstream bandwidth. The one that has the best upstream/downstream bandwidth is identified as the host for the session. If the resources are not available under the best efforts approach, then the performance of the application suffers.
SUMMARY OF THE INVENTION
[0004] In general, in one aspect, the invention features a method for managing a session over a network that involves multiple end points obtaining services via an application server. The method involves: after the end points have registered with the application server for the session, establishing initial policies for network traffic flows for each end point participating in the session; after establishing the initial policies, determining information about the network traffic flows for at least some of the multiple end points participating in the session; from the information determined about the network traffic flows, identifying which of the multiple end points is functioning as a host server for the session; and after identifying which of the multiple end points is functioning as the host server, establishing new policies for network traffic flows for the multiple end points, wherein under the new policies fewer network resources are reserved for each of the multiple end points other than and as compared to the end point functioning as the host server.
[0005] Other embodiments include one or more of the following features. Determining information about the network traffic flows for at least some of the multiple end points participating in the session involves determining the network traffic flows for each of the multiple end points participating in the session. Determining the network traffic flows involves monitoring the network traffic flows. Determining the network traffic flows involves receiving notifications from one or more other entities on the network about the network traffic flows. The initial policies specify the amount of network bandwidth reserved for each end point. Under the initial policies the same amount of network bandwidth is reserved for each of the multiple end points. The network bandwidth that is reserved for each end point exceeds an expected bandwidth required for the host server. Establishing new policies for network traffic flows for the multiple end points involves reducing the amount of bandwidth that is reserved for each of the multiple end points other that the one functioning as the host server. The network is one of a cable network, a DSL network, an FTTx network, an xPON network and a data-over-wireless network.
[0006] 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.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a block diagram of a cable network that implements the invention.
[0008] FIG. 2 is a flow chart of the process for adaptively modifying the policies regarding network traffic flows.
DETAILED DESCRIPTION
[0009] The described embodiment is a multi-point network in which end-points participate in sessions for which session requirements cannot be determined prior to the beginning of the session. The network includes a policy server that dynamically adapts the allocation of network resources based upon selective passive monitoring of the use of network resources by the end-points that are participating in the session. The described embodiment ensures a more optimal utilization of the network especially in a situation where the session requirements cannot be accurately determined prior to the beginning of the session.
[0010] As shown in FIG. 1 , the network of the described embodiment is a cable network that includes Customer Premises Equipment (CPEs) or end-point devices 10 A-C, such as personal computers or set top boxes with attached gaming devices, that subscriber's use to access the services available form a remotely located application or registration server 20 . Each end-point device is connected to a corresponding access network 14 via a cable modem (CM) 12 . Each access network 14 , in turn, includes an access network termination point 16 such as a Cable Modem Termination System (CMTS), which functions as a gateway to the access network and which communicates with application server 20 over a wide area network (WAN) 18 , such as the Internet. End-point devices 10 A-C request admission to and participate in sessions with each other through the application server. A policy server 22 , which manages admission control and Quality of Service on behalf of application server 20 , communicates with application server 20 over the WAN. In general, policy server 22 decides, based on rules configured by the operator, the network state, and subscriber information, which sessions can be admitted into the network.
[0011] There are two basic communication channels that are particularly relevant in this system. One communication channel carries communications between application server 20 and policy server 22 . The other communication channel carries communications between policy server 22 and the access network termination devices (e.g. the CMTSs for the cable world and BRAS for the DSL world). The interface between policy server 22 and application server 20 is XML, HTTP, or some other mutually agreed upon interface. This protocol would typically be a protocol that is proprietary to the entity that is providing the service. In contrast, the interface between application server 20 and the access network termination devices is typically defined by industry-adopted standards.
[0012] In the illustrated embodiment, each CPE is shown as being connected to a different access network and three separate CMTSs are involved. It should be understood, however, that this configuration is purely for illustration purposes only and is not meant to imply that other configurations are not possible. For example, the CPE's could all be on the same access network. Whether that is the case depends on where of the CPEs are geographically located. In addition, even though the CPEs might in fact be on different access networks as shown, it is possible that the three access networks connect to a different line card in the same CMTS.
[0013] The CMTS, which sits at a cable head-end of the corresponding access network, functions as a data switching system designed to route data to and from many cable modem users over a multiplexed network interface. It integrates upstream and downstream communications over the access networks (e.g. a cable data network) to which it is connected. In the described embodiment, the CMTS implements a protocol (e.g. the DOCSIS RFI MAC protocol) to connect to cable modems over the access network. DOCSIS refers to the set of Data-Over-Cable Service Interface Specifications, which defines how to transmit data over cable networks in a standard fashion (see DOCSIS1.0, 1.1, and 2.0). RFI is the DOCSIS Radio Frequency Interface specification defining MAC and Physical Layer interfaces between CMTS and CM network elements.
[0014] Application server 20 , which is typically managed by a content provider, is the entity that delivers the content to the applications running on CPEs 10 A-C connected to cable moderns 12 A-C.
[0015] Cable modems 12 A-C enable other Customer Premises Equipment (CPE) 10 A-C to connect to access networks 14 A-C and receive cable services. In the described embodiment, the cable modem is a 64/256 QAM (Quadrature Amplitude Modulation) RF receiver that is capable of delivering up to 30 to 40 Mbps of data in a 6 MHz cable channel. Data from the user is modulated using a QPSK/16 QAM transmitter with data rates from 320 kbps to 10 Mbps (where QPSK refers to Quadrature Phase Shift Keying modulation). The upstream and downstream data rates can be flexibly configured using cable modems to match subscriber needs.
[0016] Policy server 22 is a system that primarily acts as an intermediary between application server 20 and CMTS(s) 16 A-C. It applies network policies to requests from the application servers and proxies messages between the application server and the CMTSs. In the described embodiment, it implements the functionality that is specified by the Packet Cable Multimedia (PCMM) standards (e.g. see PacketCable Multimedia Architecture Framework Technical Report PKT-TR-ARCH-V01-030627) as well as the extended functionality described herein. In its capacity as an intermediary, policy server 22 grants QoS for different requesters based on policy rules established by the operator of the network or service, and affects the QoS by pushing down policy decisions to the termination devices (e.g. the CMTSs). Its extended functionality includes keeping track of and monitoring the state of the network (what is happening on the network, the state of the sessions, etc.) and making policy decisions based on the state of the network.
[0017] The application server can provide any one of a number of different services including, for example, video conferencing and online multi-player video games to name two of the more popular services. For the purpose of the following description, it is assumed that the application server is a games server (e.g. a Microsoft Xbox or a Sony Server) which supports multiple user gaming applications.
[0018] In a multipoint environment in which several endpoints are trying to share a session together, often one endpoint will ultimately function as the host. The significance of being the host server is that all other servers interact with it. The host server determines what needs to happen at all participating locations and it receives communications from all participating game servers that want to interact with other game servers in that particular instance of the game. The host server also forwards communications to all other game servers that are affected. As a consequence, the host server needs to have greater bandwidth allocated to it as compared to the game servers of the other subscribers to enable it to handle the larger volume of communications for which it will be responsible. For example, the host server might typically need twice the bandwidth of the other game servers participating in the game. Often, however, it is not known at the time that the endpoints register with the application server nor can it be determined at the beginning of the session which end-point device will function as the host. The described embodiment provides a solution to this problem as follows.
[0019] Referring to FIG. 2 , each of the end-points A, B, and C registers with server application 20 for a session that will eventually be hosted at one end-point (step 200 ). The registration involves indicating that they want to play a particular game together. The details of the registration process vary depending upon the particular application that is involved.
[0020] After the end-points have registered, application server 20 notifies policy server 22 that a session with certain specified requirements will be established between the “identified” end-points, i.e., the registered entities (step 202 ). Since the application server has no knowledge of where the session will be hosted, the application server does not identify the host at this time.
[0021] Policy server 22 initially responds to the notification from application server 20 by setting up bandwidth for a “worst-case scenario” (step 204 ). That is, in this particular example, policy server 22 treats each end-point as though it will be the host and assigns resources accordingly. In this case, the key resource is bandwidth. So, at the beginning of the session excess bandwidth is reserved for the session. In the cable network, this is achieved by setting up gates (i.e., policies or controls) at the affected CMTSs for upstream and downstream directions.
[0022] As a rule, depending on the particular application server that is being used and the application that is being run through the shared session, either the policy server or the application server will know, a priori, the bandwidth needs of the host. However, if this knowledge is not initially known, it is empirically derived from observing what resources are used by the applications during actual sessions. Based on this knowledge, whether known ahead of time or determined empirically, policy server 22 assigns bandwidth to each subscriber that is sufficient for any one of them to play the role of host. So, regardless of which entity ultimately becomes the host, the initial bandwidth assignments provide sufficient resources. Application server 20 also takes care of requesting the other parameters that are necessary for the type of session being established (e.g. latency, etc).
[0023] At the start of session, the end-points negotiate and appoint a “host” (step 206 ). Negotiation is based on whatever parameters are relevant to the session that will be set up and will typically follow a protocol that is proprietary to the specific application that is being run.
[0024] After the session has begun and in preparation for reallocating resources, policy server 22 watches bandwidth utilization by each subscriber (step 208 ). That is, policy server 22 selectively and passively monitors the end points to see how much data is being transmitted and received per flow. These measurements are made at the subscriber level and the CM and/or CMTS level, whichever is applicable. It does this, for example, by polling the counters in the MIBs at the CMs. And/or it polls appropriate counters within the data structures maintained by the CMTSs. The monitoring is passive in that it does not interfere with the functioning of the CMTS.
[0025] After policy server 22 has obtained sufficient data, it analyzes that data to identify which of the end points is functioning as the host (step 210 ). In other words, it identifies the end-point session that is handling the most traffic.
[0026] After identifying the host server, policy server 22 revises the policies that apply to this set of subscribers (step 212 ). For example, policy server 22 compares actual usage with authorized usage and it instructs the affected devices to modify the flows. In the world of cable networks that means going to the termination device, i.e., the CMTS; whereas, in the world of DSL world that means going to both the affected network access termination devices and the DSL modems. Since the goal of policy server 22 is to establish more efficient use of resources (e.g. bandwidth), it modifies the bandwidths that are reserved for the other flows so as to release the excess reserved bandwidth thereby freeing it up for use by others. The amount of bandwidth that is reserved for the various flows is dependent on policy considerations that are being implemented by the policy server or the entity that manages the policy server. Since the initial reservations were based upon the needs to the host severs, this might mean that initial reservations for the host server are left undisturbed while the reservations for the other servers are reduced. Alternatively, it might also be appropriate to modify the reservation for the host server as well (either upward or downward) if monitored traffic flows warrant such an adjustment.
[0027] After the bandwidth reservations have been modified based upon knowing which server is functioning as the host, policy server 22 continues to monitor the activity of the end-points (e.g. usage of the flows that have been set up). It does this until it detects that the transmit and receive activity has ceased for a sufficiently long time, indicating that the session has ended (step 214 ). The inactivity period is configurable by the operator and will typically depend on the actual application. Gaming, for example, tends to be very interactive and so a short period of inactivity would typically be a sufficient indication that the game is over and the flows can be to torn down.
[0028] Upon detecting that the session has ended, policy server 22 tears down the flows (step 216 ). During the tear down, policy server 22 instructs the CMTS (or other edge devices such as the B-RAS or PDSN/GGSN) to release resources making them available to other sessions.
[0029] In the embodiment just described, the policy server directly monitors the activity of the different subscribers. Alternatively, this information can be retrieved from another device in the network that may be monitoring the traffic and the bandwidth utilization associated with the subscriber and his/her sessions, in which case the policy server would not perform direct monitoring. Still another mechanism by which the policy server can learn of the information required to dynamically adjust reserved network resources is by having the devices through which the media is flowing (e.g. CMTS, routers, monitoring devices, or sniffers) notify the policy server of when certain amounts of traffic (volume) associated with the specific subscribers' sessions have passed through the device (i.e., thresholds for volume of data traversing the device has been hit). The policy server can identify which subsci-iber is consuming the most amount of bandwidth based on which session is the first to trigger such a volume usage consumption notification from the device(s) in the media path.
[0030] The above-described approaches are applicable to any network session in which one of the subscribers functions as the host and it is not known at the beginning of the session who that subscriber will be. Note, however, that the methods just described can also be applied to intelligently adjust the rate for a single point session. After a session is first set up with an approximate reservation of bandwidth, the policy server dynamically adjusts the bandwidth reserved for the session by interpreting the counters retrieved from the end-point or intermediate devices. If the counters collected from the end point and intermediate equipment indicate that data has been dropped, then the policy server knows that the reservation should be increased to ensure throughput. Alternatively, if the policy server sees that the average rate, calculated using the same counters, is below the rate that was originally reserved for the session, the policy server can dynamically decrease the reservation for the session so that excess bandwidth or resources can be reclaimed for use by other entities.
[0031] The principles described herein are not limited to cable networks but they are generally applicable to any network in which QoS is provided to the devices including, for example, DSL (Digital Subscriber Loop), FTTx (Fiber To The X), xPON (Passive Optical Network), and a data-over-wireless (e.g. a 3G wireless network). In the case of DSL networks, different devices that transport the media (called policy enforcement points) are involved but they serve similar functions to the CMTSs and CMs of the cable networks. For example, in the DSL world the policy enforcement points includes Digital Subscriber Line Access Multiplexers (DSLAMs), Asynchronous Transfer Mode (ATM) switches, Broadband Remote Access Servers (BRAS) and IP routers. Similarly, in the 3G wireless world, the PEP can be Packet Data Serving Node (PDSN), Gateway GPRS Support Node (GGSN).
[0032] Other embodiments are within the following claims. | A method for managing a session over a network that involves multiple end points obtaining services via an application server, the method involving: after the end points have registered with the application server for the session, establishing initial policies for network traffic flows for each end point participating in the session; after establishing the initial policies, determining information about the network traffic flows for at least some of the multiple end points participating in the session; from the information determined about the network traffic flows, identifying which of the multiple end points is functioning as a host server for the session; and after identifying which of the multiple end points is functioning as the host server, establishing new policies for network traffic flows for the multiple end points, wherein under the new policies fewer network resources are reserved for each of the multiple end points other than and as compared to the end point functioning as the host server. | 7 |
This application is a continuation of application Ser. No. 14/184,662 filed Feb. 19, 2014 and claims priority from my provisional application 61850566 filed Feb. 20, 2013 which is hereby incorporated by reference.
BACKGROUND
I invented a ladder leveler that provides adjustable extensions to ladder legs, U.S. Pat. No. 5,678,656. That leveler is shown in FIGS. 1 and 2 . The leveler includes an outer housing 41 secured with fastening bolts 57 to an outer ladder rail 29 which holds ladder rungs 23 . It includes a leg extension 71 that is movable within a channel 43 in the outer housing 41 from a retracted position to an extended position. It includes a positive locking engagement system including a pawl 73 mounted on a pivot pin 79 and biased into engagement by a pawl spring 81 . The pawl engages ratchet teeth 49 on a toothed ratchet bar 47 held in place by fasteners 51 in a recess 45 . The greater the force applied to the ladder rail 29 , the greater the force applied to the locking engagement between the outer housing 41 and the leg extension 71 .
A release lever 75 on the pawl 73 releases the pawl when activated by hand. A safety bar (shown in FIG. 2 without a reference numeral) extends from the center of the shaft of a bolt 33 that is bolted to a support foot 27 to the pawl 73 , contacting the pawl close to its pivot hole 77 , such that force applied to the support foot 27 presses the safety bar against the pawl 73 and locks the pawl in position.
The support foot 27 is secured to the leg extension 71 with the securing bolt 33 which acts as a hinge pin by passing through an oblong securing bolt aperture in the leg extension, and is held in place with a securing nut 35 . The support foot 27 includes a rubber friction pad tread 31 .
The leveler also includes a retraction spring 53 coupled at one end to the outer housing at a spring fastener 55 and at the other end to the leg extension 71 . The retraction spring continually applies an upward biasing force on the leg extension. To facilitate the extension and retraction of the extension leg 71 into and out of the outer housing 41 , a foot pedal 101 is secured to the front portion of the extension leg 71 with a foot pedal pivot pin 103 . Pressing on the pedal opposes the force of the retraction spring 53 .
SUMMARY OF THE INVENTION
The invention provides improvements to the leg extension of my prior ladder leveler and, more generally, improvements to ladder legs.
In one aspect, the invention is a ladder leg with a nailable, pivoting shoe, comprising a ladder leg having a bottom end with a pivotable structure at the bottom end; pivotably coupled to the pivotable structure, a ladder shoe having a planar bottom surface, the bottom surface being a surface of a support structure of the ladder shoe adapted to apply weight of the ladder to a planar surface on which the ladder rests when erected; at least one hole in the support structure, the hole passing through the support structure perpendicular to the planar bottom surface of the ladder shoe; and the hole having a minimum diameter of at least 1/16 inch and no part large enough to allow passage of a ⅜ inch sphere.
The hole may be round or a slot. The support structure may include a metal portion and a rubber portion and the rubber portion forming the planar bottom surface of the ladder shoe, in which case the at least one hole in the support structure passes through the metal portion and aligns with a hole in the rubber portion. The hole in the rubber portion may be smaller than the hole in the metal portion with which it is aligned so that the hole in the rubber portion is enlarged by entry of a penetrating object that is smaller than the hole in the metal portion but larger than the hole in the rubber portion and the penetrating object is thereby gripped by the rubber portion. The planar bottom surface of the ladder shoe may comprises multiple, discontinuous bottom surfaces in a single plane, the lowest parts of the rubber tread as shown in the figures. The support structure may include, on a top surface surrounding the hole, a raised edge that supports a head of a nail inserted into the hole such that the head can be easily engaged by a forked claw for removing the nail. The leg may be an extendable and adjustable leg.
In another aspect, the invention is a retractable ladder leveler with improved foot operable control, comprising an outer housing mountable on a bottom end of a ladder and, slidably coupled to the outer housing, an adjustable ladder leg extension having a direction of extension and an opposite direction of retraction. The outer housing and the leg extension together present a shoe-contactable boundary around the leveler defined as the limit of locations on or near the outer housing and the leg extension that can be contacted by a sphere of 7½ inches diameter (the typical curvature of the inside or outside ball of the foot of a typical shoe).
A spring is coupled to the leg extension and to the outer housing. It urges the leg extension to slide in the direction of retraction. A retaining pawl releaseably connects the outer housing and the leg extension. When the pawl is engaged, it holds the leg extension from sliding in the direction of retraction. The retaining pawl has a release lever.
A foot pedal is coupled at its proximal end via a pivot to the leg extension. The pivot and the foot pedal are configured so that, when pivoted into an action position, the foot pedal presents a foot engagable surface that is perpendicular to the direction of extension and transmits to the leg extension a force applied by a foot in opposition to the spring, causing the extension to extend.
The improvement is that the pivot and the foot pedal are further configured so that, when the foot pedal is pivoted into a non-action position, the distal end of the foot pedal protrudes to form a foot engageable ledge perpendicular to and extending at least ⅛ inch beyond the shoe-contactable boundary so that a human's shoe moving in the direction of extension along the outer housing and the leg extension will catch the foot pedal and cause it to pivot into an action position. For better functionality, the distal end of the foot pedal may protrude at least 5/16 inch beyond the outer shoe-contactable boundary, preferably 9/16 inch beyond the shoe-contactable boundary.
The release lever may also have a distal end protruding at least ¼ inch beyond the outer shoe-contactable boundary of the outer housing and the leg extension so that a human's shoe moving in the direction of extension along the outer housing and the leg extension will catch the release lever to release the pawl. The distal end of the release lever may have a lip extending in the direction of retraction so that a shoe can more easily catch and engage the release lever. For better functionality, the distal end of the release lever may protrude at least ⅜ inch beyond the outer shoe-contactable boundary, preferably 9/16 inch beyond the shoe-contactable boundary.
In another aspect, the invention is an extendable and adjustable ladder leg with an improved shoe with a claw, comprising an extendable and adjustable ladder leg extension having a longitudinal direction of extension and an opposite longitudinal direction of retraction and having a shoe hingedly coupled to a distal end of the leg extension in a way that gives the shoe a range of hinging motion with respect to the hinge and a range of longitudinal motion with respect to the leg extension. The shoe has a hinge pin that forms a hinge axis, as well as a first end that is most distant from the hinge axis, and a second end that is most distant from the first end.
The adjustable ladder leg has a safety bar slidably mounted on the leg extension and coupled to the shoe such that the safety bar moves in the direction of retraction with respect to the leg extension when the shoe moves in the direction of retraction with respect to the leg extension, the safety bar thereby preventing release of a release mechanism that, when activated, releases the leg extension to move in the direction of retraction.
The improvement comprises the shoe having a toothed claw on at least one of the first end or the second end; the shoe including cut-outs that allow the shoe to hinge 180 degrees about the hinge axis when the extension leg is fully retracted; and the shoe including retaining surfaces that contact parts of the leg extension and retain the claw in a fully hinged position when force is applied along the leg extension in the direction of retraction, urging the claw against an object which the claw grips. In addition, the shoe and leg extension parts are configured such that, when the shoe is in a fully hinged position and force is applied along the leg extension in the direction of retraction, the shoe can move toward the leg extension to actuate the safety bar and thereby prevent activation of the release mechanism.
The retaining surfaces that contact parts of the leg extension and retain the shoe in a fully hinged position may comprise part of a circumference of each of two triangular holes, one in each of two sidewalls of the shoe, which retaining surfaces contact a hinge pin coupled to the leg extension.
The triangular holes may each include at least one slope in its circumference which slope is a retaining surface that applies a lateral force to the shoe via contact with the hinge pin when weight is applied to the leg extension while the ladder leg is in an erected position and the shoe is in a fully hinged position.
The retaining surfaces that contact a part of the leg extension and retain the shoe in a fully hinged position may comprise an upper side of a support base of the shoe which upper side contacts a lower corner of the leg extension to retain the shoe in a fully hinged position. In this case, the retaining surfaces also comprise part of a circumference of each of two holes, one in each of two sidewalls of the shoe, which holes, when the shoe is in a fully hinged position, are longer in the longitudinal direction than a diameter of the hinge pin, such that the shoe can move in the direction of retraction with respect to the leg extension after the shoe is in a fully hinged position and thereby place the retaining surfaces in position to retain the shoe in a fully hinged position and simultaneously actuate the safety bar.
In another aspect, the invention is a ladder leg with an improved shoe with a claw, comprising a ladder leg having a longitudinal direction along the leg, having a bottom end, and having a shoe hingedly coupled to the bottom end of the leg in a way that gives the shoe a range of hinging motion with respect to the hinge and a range of longitudinal motion with respect to the leg, the shoe having a hinge pin that forms a hinge axis, a first end that is most distant from the hinge axis, and a second end that is most distant from the first end. The shoe has a toothed claw on at least one of the first end or the second end. The shoe and bottom end of the leg are configured to allow the shoe to hinge about the hinge axis to a point where the shoe base is parallel to the leg.
The improvement comprises: the shoe and leg each have retaining surfaces that contact each other and retain the shoe in a fully hinged position, which retaining surfaces comprise: an upper side of a support base of the shoe which upper side contacts a lower corner of the leg to retain the shoe in a fully hinged position; and a part of a circumference of each of two holes, one in each of two sidewalls of the shoe, which holes, when the shoe is in a fully hinged position, are longer in the longitudinal direction than a diameter of the hinge pin, and the part of the circumference of each of two holes contacting the hinge pin retain the shoe in a fully hinged position. In this event, the shoe can move in the direction of retraction with respect to the leg after the shoe is in a fully hinged position and thereby place the retaining surfaces in position to retain the shoe in a fully hinged position. The two holes may each be triangular in shape.
BRIEF DESCRIPTION OF THE FIGURES
FIGS. 1 and 2 show the prior art ladder leveler with an adjustable extendable leg.
FIG. 3 shows the hole in the shoe for nailing.
FIG. 4 shows two nails through the holes and through aligned holes in the rubber tread portion of the shoe.
FIG. 5 shows the conical shaped raised metal around the hole to facilitate removing the nail.
FIG. 6 shows the shoe with a triangular hole rotated 90 degrees but hanging low off the leg of the ladder.
FIG. 7 shows the shoe still rotated 90 degrees but now pushed up from below so that the leg of the ladder extends lower than the triangular hole.
FIG. 8 shows the lower foot pedal in a folded position and the upper release lever, each extending outward enough to be operable with a person's foot (shoe).
FIG. 9 shows the lower foot pedal in the unfolded position for extending the leg.
DETAILED DESCRIPTION
Ladder Shoe with Fastener Holes
As shown in FIGS. 3 and 4 , fastener holes 201 in the ladder shoe allow nails or screws or other fasteners to be inserted into dirt or wood or other material on which the ladder is erected to provide extra grip. Instead of holes, slots may be placed in the shoe. Most ladder shoes include a rubber tread 31 below a metal support structure 27 . The tread may also have aligned holes so the nails can pass through both the metal structure and the rubber tread as shown in FIG. 4 . These holes in both the metal and the rubber tread make the shoe lighter, which is always a design advantage for ladders. The holes are located near the ends of the shoe, large enough to slide a nail or similar, sharp or narrow, or thin metal or plastic piece through the hole or holes to penetrate a slippery surface, thereby providing additional non-slip features to the bottom surface of the shoe. The shoe will preferably include a claw on each end as shown in FIGS. 3 and 4 , and the holes are near the claws.
The hole or slot in the metal portion of the shoe can be the same size or slightly larger than the penetrating object, (i.e. 16d framing nail) to minimize any friction between the two objects, but the rubber tread underneath the metal portion can be slightly smaller than the penetrating object so that the rubber tread grips the penetrating object tightly, thereby minimizing the chance of it sliding back up and out too easily.
The penetrating object may be slid into the hole or slot when a ladder or leveler is set up on a slippery surface, as an added safety measure. An example would be setting up a ladder on a mossy deck. A nail can be slid through the leveler shoe hole and in between the grooves in between deck boards. A 16d framing nail, or sinker, is the most common nail found on a construction site, used for general framing, temporary scaffolding, saw horses, etc. A 16d framing nail placed in a slightly larger hole in the metal, a slightly smaller hole in the tread make the best combination of holes and penetrating devices.
Additionally, as shown in FIG. 5 , the hole or holes in the shoe bottom can also have an upward protruding, semi-conical shape to allow easy removal of the nail. The smallest diameter portion of the semi-conical protrusion is located above the flat metal surface of the bottom portion of the shoe. This holds the head of the nail up and above the flat surface of the metal portion of the shoe, thereby enabling the claw of a hammer to grasp under the head of the nail to pull the nail more easily. A standard concrete form nail, with a double head, is another possible solution if a hole without the semi-conical shape is used in the shoe.
The rubber tread 31 located under the bottom, metal surface of the leveler shoe, and riveted on, also has holes of a slightly smaller diameter, in line with the holes in the metal portion of the shoe, so that the nail can penetrate all the way though the shoe assembly, including the holes in rubber tread, and in between deck boards, or the nail can be pounded into a wood surface, such as a subfloor on a new building or on a sheathed roof (sloped or not) of a new structure. The nails can also be used to penetrate into a lawn or any other soft surface that may be wet, moldy, mossy and/or slippery. These holes can also be shaped as slots that would enable a shim or other sharp device to be slid through to act as a securing, or non-skid device.
Claw Foot Locks in 90 Degree Rotation
As shown in FIGS. 6 and 7 , the shoe has been modified to enable it to pivot 90 degrees in one direction, or 90 degrees in the opposite direction, totaling a potential pivoting action of 180 degrees, without the need to extend leg extension when leg extension is fully retracted in the “ready” position and to slide up and down when pivoted 90 degrees. This feature enables the shoe to function as a claw that works in conjunction with the automatic, back-up safety mechanism of the leveler with extendable leg or with any ladder leg having a square bottom end of the leg.
The shoe has specially designed shapes and sizes, with carefully designed relationships between the shapes and sizes, including an elongated hole 205 through which a hinge pin couples the shoe to the ladder leg. When used together, these shapes and sizes and holes enable the bottom tread/claw surface and assembly of the shoe to pivot into the parallel position, in relation to the leg, and then, once pivoted into a parallel position, upward force applied to a claw end of the shoe will slide the shoe upward, the elongated hole allowing the hinge pin to move downward in the hole as shown in FIG. 7 , so that a lower corner of the square bottom of the ladder leg 206 contacts the shoe bottom structure to prevent the shoe from pivoting out of the parallel position. The contact surfaces which retrain the shoe in position are a bottom corner of the ladder leg 206 contacting the inside of the horizontal base plate of the shoe and a portion of the inner circumference of the elongated hole 205 contacting the hinge pin (which is bolt 33 in the preferred embodiment). The hole 205 is elongated in a direction parallel to the shoe base and may also be triangular as shown in FIGS. 6 and 7 .
In effect, the shoe becomes wrapped around the lower, outer leg, thus pointing the claw, on the desired end of the shoe, downward toward, and/or into the slippery surface on which the ladder is erected. These special shapes and dimensions allow the shoe to pivot and wrap around the bottom end of the lower leg, while working together with the automatic, back-up safety mechanism, and without any type of interference between the leveler leg, safety mechanism or shoe assembly. Both the shoe locking system and the release lever locking system will remain locked in their respective positions until weight is removed from the ladder leveler.
These new features provide a ladder leveler with a shoe and an automatic, back-up safety lock, having metal claws on either one or both ends of shoe, with the ability to pivot 180 degrees, slide up and down the leveler leg assembly and remain locked parallel to the leveler leg, thereby enabling the claw to dig into ice, snow or other slippery surfaces without concern for accidentally tripping the shoe to the flat position while on the ladder and without concern for retracting the leg extension.
There are various ways to achieve these results, including, but not limited to A.) specially designed, triangular shaped holes in two side flanges of leveler shoe as shown in FIGS. 6 and 7 ; B.) specially shaped and sized side flanges of the shoe; and C.) specially shaped and sized bottom support structure of the ladder shoe (attached to rubber tread). The shoe, with claw facing downward and penetrating or contacting a support surface, will not flatten out (down) when any weight or load is being applied to the ladder leveler, even if a load, sudden or otherwise, is applied from a direction that is different from the angle of the ladder leveler legs. The end result is that the claw shoe, automatic safety lock and primary ratchet lock all remain in the locked position as long as weight or load is applied to the ladder leveler leg or the ladder to which the leveler leg is attached, even if the load (sudden or gradual) is applied to the side, back, front or top of the ladder leveler or ladder to which the ladder leveler is attached.
This invention provides much more versatility in the ladder leveler because it enables the ladder user to quickly and easily flip the leveler shoe all the way back or forward, allowing the inside, upper surface of the bottom portion of the shoe to slide up against the leg, thereby activating the automatic, back-up, safety mechanism up against the pawl (and its release lever), thereby keeping the pawl locked, without the need to extend the leg extension several inches beforehand. This option enables a ladder user, who prefers not to extend the leveler leg, to easily use the claw on either end of the shoe (double claw shoe—front and back) when setting up a ladder on flat, even surfaces, or uneven surfaces, with ladder levelers that have automatic, back-up safety mechanisms installed.
Lever Controls Actuatable with a Person's Foot
As shown in FIGS. 8 and 9 , the release lever 75 , which is the upper of the two levers, is modified in its length and its shape so that it protrudes at least ¼″, better ⅜″, preferably 9/16″, but not more than 1″, beyond the shoe-contactable boundary of the leveler, creating a preferred relationship between the outer surfaces of the leveler and outer portion of the release lever. Preferably, the tip of the lever 209 has a upward curve. This improvement enables the user to depress the lever with his or her foot, shoe or toe, more quickly, ergonomically and with less physical effort. The proximity and immediate relationship between the two parts (outer surface of the leveler and the release lever) is critically important in how the locking system will respond when touched with a foot, and also in relation to the automatic, back-up, safety mechanism, which is deactivated when weight (load) is removed from the leveler shoe.
The increased length of the release lever adds significantly to the ease of operation by creating quick and easy access to the lever, even when a person with large feet (large shoes) is attempting to depress the lever to release the locking system and retract the leg extension. The slight upward bend 209 in the release lever, located approximately ¼″ from the outermost tip of the lever, creates an angled edge for shoes that may be slippery from being wet, muddy or smooth from wear that is much easier to snag with a foot or toe. Additionally, the top surface of the lever, including the upwardly curved tip 209 , has grooves in it for extra grip. The release lever is also shaped so that it will not protrude from the outside face of the ladder leveler to a point at which it would be considered overly obtrusive, thereby creating interference, when the leveler is not in use and/or the ladder and leveler combination is being carried or stored.
As shown in FIGS. 8 and 9 , the foot pedal 101 , which is the lower of the two levers, is modified in its length and its shape to enable the ladder user to quickly and easily catch the foot pedal of a ladder leveler with the bottom of a shoe or side of a shoe when the foot pedal needs to be snapped downward to the “READY” position for quickly extending the inner ladder leveler leg, thereby creating a faster, safer leveling operation without the need to bend over to use a hand to snap the foot pedal down into the “READY” position.
The proximity and immediate relationship between the two parts (leveler's outer surface and the foot pedal) is critically important in how the foot pedal/locking system will respond when touched with a foot or shoe, particularly in relation to the automatic, back-up, safety mechanism, which is deactivated when weight (load) is removed from the leveler shoe, and activated when weight is placed on the leveler shoe. The special shape is designed so that it is easier to snap up and snap down with a foot, while activating or deactivating the back-up, automatic safety mechanism. This special shape, combined with the extra length (at least ⅛″ beyond the shoe-contactable boundary of the leveler, better 5/16″, preferably 9/16″, and no more than 1″ beyond the shoe-contactable boundary the leveler) is a more ergonomic shape, is easier to reach, and is combined with grooves running perpendicular to the length of the foot pedal for added non-slip features. The foot pedal is also shaped so that it will not protrude from the outside face of the ladder leveler to a point at which it would be considered overly obtrusive, thereby creating interference, when the leveler is not in use and/or the ladder and leveler combination is being carried or stored. | Improvements to the leg extension of an adjustable ladder leveler and, more generally, improvements to ladder legs. A shoe with a claw that folds to be parallel to the ladder leg and then slides upward with respect to the leg thereby becoming locked into position so that it cannot move away from being parallel so long as weight is applied on the ladder. If the shoe is on an extension, as the shoe slides up, it engages a safety bar that prevents release of the extension. | 4 |
FIELD OF THE INVENTION
The present invention relates generally to storage and dispensing systems in which specific absorbable gases, including but not limited to gaseous fuel, gaseous hydrocarbons, methane, and hydrogen, are sorptively retained by a solid sorbent medium.
BACKGROUND OF THE INVENTION
Natural gas (NG) is a promising alternative fuel. Unfortunately, natural gas is often difficult to store, and natural gas storage requires extremely high pressures and/or at very low temperatures. To date, two techniques for NG storage are commercially used.
The first storage technique is to store Compressed Natural Gas (CNG) under extremely high pressure conditions such as, for example, 200-250 bars at normal ambient temperature. These pressures require specially designed reinforced tanks, which are bulky and heavy. Furthermore, gas compression requires an expensive and multi-stage high-pressure compression process. High-pressure vessels containing compressed natural gas are known to present a significant fire and/or detonation hazard.
Alternatively, Liquefied Natural Gas (LNG) is refrigerated to −161.5.degree. C. and stored at a more moderate pressure. This technique entails use of complex and expensive liquefaction equipment and thermos-like tanks as well as significant energy consumption (15-25% of the original gas energy content) for both liquefaction and regasification of the gas.
Both CNG and LNG technologies employ cylindrical or spherical storage tanks that lead to waste of space between neighboring vessels in arrays.
absorbed natural gas (ANG) is a promising alternative to these aforementioned technologies for natural gas storage since the same quantity of NG can be stored at much lower pressure (35-40 bars), at room temperature and in a thinner walled tank with a lower pressure rating. Furthermore, this method does not require expensive and cumbersome gas compression or liquefaction equipment, insulated tanks, etc. ANG tanks could have any configuration in contrast with exclusively cylindrical forms of NG high-pressure tanks. Thus, the tanks could be tailored to fit odd spaces, such as today's gasoline or diesel tanks in cars.
Salient features of ANG technology include high sorbent property and the thermal management system embedded within the vessel. ANG systems are thus characterized by the sorbent's ability for uptake and delivery of a maximum gas quantity. To date, sorbents based on activated carbon have shown promise. It is desirable to maximize the microporosity (fraction of the micropore volume) of the sorbent material so that the space occupied by the atoms of the microporous material and the space wasted by poor packing of the crystallites are both minimized.
For the specific case of adsorptive storage of natural gas, the efficacy of the absorbent in majority cases is measured by the adsorption capacity for gas per unit volume of absorbent at a specified pressure and room temperature. The adsorption capacity per unit volume of absorbent can be calculated by V.sub.v=(V.sub.w)(d), where Vw is the adsorption capacity of the material per unit mass of absorbent, and d is the density of the absorbent pellets. Upon compacting the material, the density d is increased, and so the adsorption capacity per unit volume V.sub.v also increases.
Primarily activated carbon sorbent is supplied in particulate matter such as powder or granulated powder form. Since volumetric performance is deciding factor in majority applications, especially for on-board fuel tanks, the sorbent needs to be compacted (immobilized).
Direct placement of the packed absorbent carbon into the storage vessel with a sufficient sorbent density has proven to be a formidable task. Briquetting, or immobilizing, the carbon was considered as an alternative. The advantages of briquetting were twofold Immobilized carbon would not settle and/or circulate in the storage vessel and would be less likely to be carried in the gas stream during discharge. Use of immobilized carbon would also allow the vessel to be packed more easily to a higher density than using just granular or powdered carbon.
Therefore, currently generally adopted tank design is based on multicell concept ( FIG. 1 ), where the tank housing 1 a includes of plurality of cells 6 and each cell in itself serves both as a pressurized vessel for the gas storing and as a container for sorbent briquettes 3 a . This concept faces two serious difficulties.
The first difficulty is the complex design of the tank housing, whose manufacturing requires special profiling using expensive cumbersome equipment. The second is requirement that of high mechanical strength of the sorbent blocks.
In order to imbue sorbent blocks with the requisite mechanical strength, a significant quantity of binding medium is added to the sorbent. The use of a chemical binder, however, detracts from absorbent performance, because the binder tends to block methane access to the micropores of the carbon resulting in reduced storage and delivery. Furthermore, addition of binding material increases the size of the sorbent blocks without concomitantly increasing the amount of gas absorbent material within each block.
There is an ongoing need for absorbing gas storage systems including mechanically stable sorbent units within a storage tank. Current techniques do not provide viable solutions to this ongoing need, since on the one hand high-strength briquettes require strong binding material, and on other hand this binder concomitantly decreases sorbent uptake. Other technology for compensating for performance degradation associated with chemical binder use is very complex and expensive and still does not give desired results.
Furthermore, there is an ongoing need for absorbing gas storage systems designed to reduce the amount of time required to absorb and/or desorb adorable gas such as methane onto and/or from the sorbent, in order to reduce the time of filling the tank and/or removing the gas from the tank. It is noted that adsorption of methane gas onto the sorbent is an exothermic process, and thus as the gas is absorbed to the sorbent the ambient temperature within the storage tank increases, diminishing the rate of methane uptake by the sorbent. Similarly, desorption of gas reduces the ambient pressure and temperature within the tank, concomitantly increasing the time necessary to deliver absorbed gas from the tank. There is an ongoing need for systems and methods for removing heat from the tank during gas adsorption and for delivering heat to the tank during gas desorption. Preferably, the delivery and removal of heat should be relatively uniform throughout the tank in order to provide optimal conditions for all sorbent units within the vessel.
The following patents and published patent document, each of which are incorporated herein by reference, provide potentially relevant background art:
U.S. Pat. No. 6,019,823 discloses solid-phase physical sorbent medium holding absorbed fluid is provided in a cartridge, for use in a sorbent-based fluid storage and dispensing system;
SUMMARY OF THE INVENTION
The aforementioned needs are satisfied by several aspects of the present invention.
A gas storage system is now disclosed including a storage tank, a gaseous fuel including an absorbing gas stored in the storage tank at an given total gas pressure, and a plurality of briquette units situated within the storage tank for absorbing the gaseous fuel.
In some embodiments, each briquette unit includes an at least partially open vessel formed or constructed such that any sealing of this open vessel produces a closed vessel with a pressure rating that is less than the given total gas pressure within the tank, and compressed particulate matter for absorbing the gaseous fuel situated within the vessel.
Exemplary gaseous fuels include but are not limited to gaseous hydrocarbons such as methane gas and hydrogen gas.
In some embodiments, the compressed particulate matter includes methane absorbing compressed particulate matter such as activated carbon. Alternatively, the compressed particulate matter includes hydrogen-absorbing compressed particulate matter such as reversible metal hydrides.
It is noted that the open vessels or liners of the briquette units provided by embodiments of the present invention provide external support to the compressed gaseous fuel-absorbing powder, obviating the need for binder additives. Nevertheless, the open vessels or liners of the present invention are not required to have any extra mechanical strength beyond what is necessary to contribute to maintaining the form of the briquette units. Thus, the open vessels or liners of the present invention are not pressure tight vessels, nor are the open vessels or liners required to have a mechanical properties associated with pressure tight vessels for bearing a pressure difference equal to or approximately equal to the total ambient pressure within the external storage tank or the partial pressure of the gaseous fuel. Thus, unlike systems which provide a pressurized tank within a pressurized tank, the gas storage systems of the present invention do not impose these stringent requirements on the briquette units, thereby providing a cost savings in the cost of the liner, and thereby allowing for thinner liners which waste less space.
In some embodiments, any sealing of the open vessel produces a closed vessel with a pressure rating that less than a partial pressure of the gaseous fuel.
In some embodiments, any sealing of the open vessel produces a closed vessel with a pressure rating that is at least 50% less than a pressure selected from the group consisting of the given total gas pressure and a partial pressure of the absorbing gaseous fuel.
In some embodiments, there is a clearance between an outer surface of the vessel and an inner surface of the storage tank. Not wishing to be bound by any particular theory, it is noted that this clearance provides for thermal insulation of the briquette units from the external environment outside of the storage tank.
In some embodiments, the partially open vessel includes a plurality of apertures for diffusion of absorbing gaseous fuel to the compressed particulate matter.
In some embodiments, the compressed particulate matter has been compressed to form an at least partially self supporting aggregate.
In some embodiments, the compressed particulate matter has been compressed beyond a pressure equal to a local pressure or open vessel pressure rating of the open vessel.
Optionally, each briquette unit includes a wrapper associated with the vessel to form a gas porous enclosure of particulate matter for preventing circulation of the particulate matter.
In some embodiments, the compressed particulate matter includes a chemical binder material.
In some embodiments, the compressed particulate matter includes at least one of compressed powder and compressed granules.
In some embodiments, the storage system further comprises a mechanism for supplying heat to or removing heat from at least one briquette unit.
There are no restrictions on the heat transfer mechanism. In some embodiments, the heat transfer mechanism includes at least one channel for transporting gas and/or fluid, where the channel traverses through a briquette unit.
In some embodiments, the heat transfer mechanism includes at least one heat transferring carrier selected from the group consisting of a gas channel, a heat pipe and a fluid channel.
In some embodiments, the heat transferring carrier plays a role of a bearing element for the open vessel.
In some embodiments, the bearing element bears the vessel directly.
In some embodiments, the bearing element bears the vessel through a mating part including a good heat conductor.
In some embodiments, the mechanism includes at least one of a heat source and a heat sink placed outside of the storage tank.
In some embodiments, at least one of the heat source and heat sink can be represented as an electric heater, a liquid fuel heater, a gaseous fuel heater, an air heat exchanger and a water heat exchanger.
In some embodiments, the compressed particulate matter is situated within the vessel so that there is no clearance between an inner surface of the vessel and an outer surface of the compressed particulate matter. Not wishing to be bound by any particular theory, it is noted that this direct contact between the compressed particulate matter and surrounding heat conducting vessel which the particulate matter is place serves to enhance the transfer of heat to and from the briquette unit, thereby bolstering the effectiveness of the heat transfer mechanism.
It is now disclosed for the first time a gas storage system including a storage tank having a pressure rating and a plurality of briquette units situated within the storage tank, each briquette unit including an at least partially open vessel constructed such that any sealing of the open vessel produces a closed vessel with a pressure rating that is less than the pressure rating of the storage tank, and compressed particulate matter for absorbing a gaseous fuel selected from the group consisting of a gaseous hydrocarbon fuel and hydrogen situated within the vessel.
In some embodiments, the open vessel is formed such that any sealing of the open vessel produces a closed vessel with a pressure rating that is at least 20% less than the pressure rating of the storage tank.
It is now disclosed for the first time a gas storage system including a storage tank and a plurality of briquette units situated within the storage tank.
In some embodiments, each briquette unit includes a liner and compressed gaseous fuel absorbing particulate matter, where the liner includes a plurality of apertures for as diffusion and provides external support to the compressed particulate matter.
In some embodiments, the gaseous fuel absorbing particulate matter is compressed to form an at least partially self supporting aggregate.
In some embodiments, the liner contributes to maintaining the form of the briquette units.
In some embodiments, for at least one the briquette unit, a majority of an inner surface of the liner contacts a surface of the compressed particulate matter.
In some embodiments, the liner does not form part of a pressure tight vessel.
It is now disclosed for the first time a gas storage system including a storage tank having a pressure rating; and a plurality of briquette units situated within the storage tank. In some embodiments, each briquette unit includes an at feast partially open vessel, and particulate matter for absorbing a gaseous fuel selected from the group consisting of a gaseous hydrocarbon fuel and hydrogen situated within the vessel, wherein the particulate matter has been compressed beyond a pressure that is equal to a local pressure rating the of the open vessel.
It is now disclosed for the first time a gas storage system including a storage tank and a plurality of briquette units situated within the storage tank. Each briquette unit includes compressed gaseous fuel absorbing particulate matter, a liner providing external support to the compressed particulate matter, and a wrapper associated with the liner to form a gas porous enclosure of the particulate matter for preventing circulation of the particulate matter.
It is now disclosed for the first time a gas storage system including a storage tank and a plurality of briquette units situated within the storage tank. Each briquette unit includes compressed gaseous fuel absorbing particulate matter, a liner providing external support to the compressed particulate matter, and a wrapper associated with the liner to form a Gas porous enclosure of the particulate matter for preventing circulation of the particulate matter.
It is now disclosed for the first time a gas storage system including a storage tank and a plurality of briquette units situated within the storage tank. Each briquette unit includes compressed gaseous-fuel absorbing particulate matter, and a gas porous enclosing liner for providing external support to the compressed particulate matter.
It is now disclosed for the first time a gas storage system including a storage tank and a plurality of briquette units situated within the storage tank. Each briquette unit includes compressed gaseous-fuel absorbing particulate matter, a liner for providing external support to the compressed particulate matter, and at least one channel through the briquette unit for fluid or gas flow. It is noted that fluid or gas flow through the channel is useful to transport heat to or remove heat from the briquette unit.
Exemplary applications of the absorbed natural gas technology of embodiments of the present invention include but are not limited to as an onboard gas tank for motorized vehicles such as trucks, automobiles, buses and armored vehicles, as a virtual pipeline for commercial and household consumers, and for marine gas transportation.
It is now disclosed for the first time a motorized vehicle including a motor powered by a gaseous fuel selected from the group consisting of a gaseous hydrocarbon, methane and hydrogen, an on-board gas storage system including a storage tank and a plurality of briquette units situated within the storage tank, and a mechanism for delivering said gaseous fuel from the gas storage system to the motor. In some embodiments, each briquette unit includes a liner and compressed particulate matter for absorbing the gaseous fuel, where the liner provides external support to the compressed particulate matter.
It is now disclosed for the first time a method of assembling a system for storage of a gaseous fuel selected from the group consisting of a gaseous hydrocarbon, methane and hydrogen. The presently disclosed method includes providing gaseous fuel-absorbing particulate matter within a supportive liner within a mold or rigid mold, forming a briquette from the particulate matter within the supportive liner, removing the briquette associated with said supportive liner from said mold, and deploying the briquette associated with the supportive liner in a storage tank.
In some embodiments, the stage of forming includes applying a compressive force to the gas fuel absorbing particulate matter to form the briquette.
After the stage of deploying, the method optionally further includes adding gaseous fuel to the storage tank to absorb on the briquette.
It is now disclosed for the first time a method of assembling a system for storage of a gaseous fuel selected from the group consisting of a gaseous hydrocarbon, methane and hydrogen. The presently disclosed method includes providing gaseous fuel-absorbing particulate matter within a supportive liner, forming a briquette from the particulate matter within the supportive liner, and deploying the briquette associated with the supportive liner in a storage tank. In some embodiments, the stage of deploying includes inserting the briquette into the tank, and the briquette is substantially free of absorbed gaseous fuel at a time of the inserting.
After the stage of deploying, the method optionally further includes adding gaseous fuel to the storage tank to absorb on the briquette.
These and further embodiments will be apparent from the detailed description and examples that follow.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 provides a diagram of a multicell tank including of plurality of cells wherein each cell in itself serves both as a pressurized vessel for the gas storing and as a container for sorbent briquettes.
FIG. 2 provides a diagram of an absorbing gas storage system according to certain embodiments of the present invention.
FIGS. 3A, 3B, and 3C provide diagrams of several exemplary manufacturing processes for creating an absorbing gas storage system.
FIG. 4 provides a diagram of an exemplary mold system for compressing particulate matter such that a channel traverses the compressed particulate matter.
FIG. 5 provides a diagram of an absorbing gas storage system according to exemplary embodiments of the present invention.
FIG. 6 provides a diagram of an exemplary heat transfer system according to exemplary embodiments of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
It has been discovered in accordance with certain embodiments of the present invention that a storage tank containing one or more briquette units, where each briquette unit includes compressed gas-absorbing particulate matter associated with a liner for maintaining the form of the briquette unit, is a useful system for storage of absorbing gases such as natural gas and hydrogen. Although the present invention does not preclude the use of binder additive such as a polymer binder or other chemical binder for maintaining the integrity of the briquette units, it is noted that, surprisingly, such binder additives are not required for practice of the present invention. Not wishing to be bound by any particular theory, it is noted that in certain embodiments, binder materials can degrade absorbent performance of sorbent briquette units, and thus it is useful for the compressed particulate matter such as compressed absorbent granules or compressed absorbent powder to derive external support to maintain its form from a supportive envelop, liner, shell, sheath, vessel, or membrane.
Any appropriate material known in the art of any appropriate thickness for providing mechanical support for compressed particulate matter is appropriate for the liner or open vessel of the briquette unit. In some embodiments, the liner or open vessel includes a good heat conductor, such as, for example, a metal or heat conducting plastic. Exemplary material include but are not limited to aluminum, carbon steel, stainless steel, titanium, magnesium, zinc, and copper. In some embodiments, the liner or open vessel includes a poor or moderate heat conductor laminated with a material of higher heat conductivity.
Furthermore, it is noted that the principles of the present invention can be applied to any compressed gas absorbing particulate matter. Exemplary gas absorbing materials include but are not limited to carbon such as activated carbon, zeolite, clays, alumina, and silica gel.
Referring now to the drawings, FIG. 2 provides a diagram of an exemplary one volume storage tank for storage of absorbed gas such as absorbed natural gas. Although the exemplary storage tank 1 illustrated in FIG. 2 is a one volume tank, this is by no means a limitation of the present invention, and in some embodiments, a multicell tank storage tank is provided.
There is no particular restriction on the material from which the tank housing 1 b is constructed. Exemplary materials include but are not limited to metal, composite, polymer materials and combinations thereof.
As illustrated in FIG. 2 , the tank housing 1 b is a unitized block of prismatic form, which is closed from one side with cap 32 . A plurality of briquette units including compressed particulate matter is located inside the tank housing 1 b with optional clearance space 42 between the outside surface of the shells or liners and the inside surface of the tank housing Not wishing to be bound by any particular theory, it is noted that the presence of the clearance space 42 helps to insulate the briquette units from the environment outside of the tank housing 1 b.
It is noted that the briquette units as illustrated are selectively deployable within the tank housing 1 b.
It will be appreciated that any shape and size is appropriate both for the storage tank 1 b in which the plurality of briquettes are placed, in contrast to the CNG systems wherein a cylindrical tank shape is a requirement. Thus, the prismatic shaped tank 1 b as illustrated is merely provided as an illustration, and is not intended as a limitation on the shape of the tank. Other appropriate shapes include but are not limited to spherical and cylindrical, and it is noted that the tank 1 b in some embodiments includes combination of these of other shaped tanks. Similarly, any appropriate shape or size is appropriate for the open container or liner from which compressed particulate matter derives mechanical support. In some embodiments, the open container or liner is shaped so as to let a heat pipe or channel traverse through the briquette unit.
Each briquette unit 3 b depicted in FIG. 2 includes a liner, shell or open vessel 4 of heat-conducting material and sorbent bed 15 including compressed particulate matter located inside the liner. Optionally, the liner includes a plurality of holes or apertures of relatively small diameter made in the vessel or liner walls (not shown) for great gas diffusion to the compressed particulate matter. Optionally, the upper portion of the vessel is closed by a lid 77 to prevent circulation of gas-absorbing particulate matter within the tank, though the closure does not need to form a hermetic sealing to produce a pressure tight vessel. Additionally or alternatively, the liner, envelope or vessel includes taco halves joined by welding, bonding or any other method, wherein the halves can be lower and upper halves or sidelong halves (for example, semi-cylindrical halves).
Alternatively or additionally, each briquette unit is enclosed with a wrapper for preventing circulation of said particulate matter in the tank, where any material for forming a gas porous enclosure is appropriate for the wrapper. Exemplary materials include but are not limited to fabric and netting. Not wishing to be bound by any particular theory, it is noted that for embodiments wherein there is a chance that the storage tank will be subjected to sudden motion, such as embodiments providing an on-board storage tank within a moving vehicle, it is useful to wrapper the briquette unit to prevent a situation wherein a chunk or bits of compressed particulate matter breaks away from the briquette unit and circulates throughout the storage tank.
Not only is there no specific requirement that the open vessel or liner associated with the compressed gas-absorbing particulate matter form a pressure tight system, but there is no limitation on the mechanical properties of the vessel or liner relative to the ambient pressure of any of the gases within the storage tank or relative to the pressure rating of the storage tank itself. Thus, in some embodiments, the local pressure-rating of every location in the liner or open vessel is less than the partial ambient pressure of absorbing gas within the external storage tank 1 b and/or less than the total ambient pressure within the external storage tank in which the liner or open vessel is placed.
As used herein, a “local pressure rating” or “open vessel pressure rating” or “non closed vessel pressure rating” of an object with an inner surface and an outer surface such as a liner, membrane, and a open vessel is the greatest pressure rating of any closed pressure-tight vessel obtained by any sealing of object such that the entire object bears the force of any pressure differential between the inner and outer surface.
It is understood that any sealing of the object includes addition of material to the object such that the object forms a pressure-tight closed vessel, and that there is no restriction on the strength or thickness of the “sealing” material. The local pressure rating refers to the maximum pressure rating obtainable by forming a closed vessel. Furthermore, it is noted that the concept of sealing to form a closed vessel is not restricted to liners or open vessels that are mostly closed, but a local pressure rating of an object is defined as the maximum pressure rating obtainable by adding any amount of any material to form a closed object where the entire object itself bears the force of any pressure differential between the inner and outer surface.
Thus, there are no specific requirements for the local pressure rating of the liner or open vessel from which the compressed particulate matter derives external mechanical support. This allows for usage of liners or open vessels with a local pressure rating that is less than the ambient pressure of the absorbing gas and/or the total ambient pressure within the external storage tank.
This allows for usage of liners or open vessels with thin walls designed to withstand to local pressure rating that is much less than the ambient pressure of the absorbing gas and/or the total ambient pressure within the external storage tank.
This furthermore allows for the usage of liners or open vessels with a local pressure rating that is less than the pressure rating of the external storage tanks in which the briquette units are situated. The only restriction on the material and thickness of the liner or open vessel of the briquette unit is that sufficient external mechanical support is provided to the compressed particulate matter. Thus, in some embodiments, the local pressure rating of the liner or open vessel is significantly less, such as, for example, 20% less or 40% or 50% less or 60% less or 80% less, than the ambient gas pressure within the external storage tank or the partial pressure of absorbing gas within the external storage tank or the total ambient pressure within the external storage tank or the pressure rating of the external storage tank.
There is no specific restriction on the degree of compression characterizing the compressed particulate matter associated with the liner or situated in the open vessel. In particular embodiments, the compressed particulate matter has been compressed with a pressure beyond the local pressure rating of the supportive liner or the open vessel of the briquette unit.
Furthermore, it is noted that there is no restriction on the pressure rating of the external storage tank, the pressure of absorbing gas within the tank, or the total ambient pressure within the tank. In some exemplary embodiments, natural gas is stored in the storage tank at pressures between 10 bar and 50 bar. In some exemplary embodiments, natural gas is stored in the storage tank at pressures greater than 80 bar Similarly, there is no restriction upon the temperature at which the absorbing gas is stored in the briquette. In some exemplary embodiments, natural gas is stored at room temperature.
Exemplary Method for Manufacturing Briquette Units
There is no restriction on the process for manufacturing the aforementioned systems for storing absorbing gas. Nevertheless, embodiments of the present invention also provide a manufacturing process for forming this gas storage system.
FIG. 3A illustrates one exemplary manufacturing process including providing the liner, membrane or open vessel ( 4 ) (STEP 1 A), situating gas absorbing particulate matter 54 such as natural gas absorbing powder within the liner or open vessel (STEP 2 A), applying pressure to the gas particulate matter 53 (STEP 3 A) in order to form compressed gas absorbing matter 43 (STEP 4 A) Subsequently, a plurality of briquette units 3 B including the compressed natural gas-absorbing particulate matter 43 are placed ( FIG. 5C , STEP 5 A) into a storage tank 1 B.
FIG. 3B illustrates an alternative exemplary manufacturing process including providing the liner or open vessel ( 4 ) (STEP 1 B) within a reinforcing mold 54 , situating gas absorbing particulate matter 53 such as natural gas absorbing powder within the liner or open vessel (STEP 2 B), applying pressure to the gas particulate matter 53 (STEP 3 B) in order to form compressed gas absorbing matter 43 (STEP 4 B). Subsequently, a plurality of briquette units 3 B including the compressed natural gas-absorbing particulate matter are placed ( FIG. 3C , STEP 5 B) into a storage tank 1 B.
Optionally, the liner or open vessel 4 provided is able to withstand the pressure applied in STEP 3 A without suffering permanent deformation. It is noted that although the external mold 53 of the process in FIG. 3B provided external support for the liner or open vessel 4 during the step whereby pressure is applied (STEP 3 B), there is no requirement that the external mold 53 of FIG. 3B be subsequently placed in the external storage tank 1 B, especially if the liner or open vessel suffices to provide the necessary mechanical support for the compressed gas-absorbing matter of the briquette unit.
It is further noted that the shapes illustrated in FIGS. 2-3 are merely exemplary shapes, and that any appropriate shape for the liner or open vessel 4 of the briquette unit is appropriate for the practice of the present invention. Furthermore, it is noted that there is no specific size restriction whatsoever on the liner or open vessel 4 . In one specific exemplary embodiment wherein compressed activated carbon powder is used to absorb methane gas in a tank embedded in an automobile, the volume of the compressed particulate matter in each briquette unit is about 600 cm.sup.3.
FIG. 4 provides a diagram of an exemplary mold system for compressing particulate matter such that a channel traverses the briquette unit or the compressed particulate matter.
FIG. 5 provides a diagram of an absorbing gas storage system according to exemplary embodiments of the present invention. In some embodiments, the storage system of FIG. 5 is appropriate for on board natural gas storage in a motorized vehicle.
FIG. 6 provides a diagram of parts of an exemplary heat transfer system according to exemplary embodiments of the present invention.
In the description and claims of the present application, each of the verbs, “comprise” “include” and “have”, and conjugates thereof are used to indicate that the object or objects of the verb are not necessarily a complete listing of members, components, elements or parts of the subject or subjects of the verb.
The present invention has been described using detailed descriptions of embodiments thereof that are provided by way of example and are not intended to limit the scope of the invention. The described embodiments comprise different features, not all of which are required in all embodiments of the invention. Some embodiments of the present invention utilize only some of the features or possible combinations of the features. Variations of embodiments of the present invention that are described and embodiments of the present invention comprising different combinations of features noted in the described embodiments will occur to persons of the art. The scope of the invention is limited only by the following claims. | A storage system for an absorbing gas including a plurality briquette units situated within the storage tank is disclosed. In some embodiments, each briquette unit includes a liner or open vessel, and compressed gas-absorbing particulate matter associated with the liner for external support. In some embodiments, the liner or vessel maintains the form of the briquette unit. The liner or vessel do not form a pressure tight vessel, and in some embodiments, the local pressure rating of the liner or vessel is less than the gas pressure within the storage tank. Exemplary gas-absorbing materials include but are not limited to methane and hydrogen adsorbing materials such as activated carbon, zeolite, and other appropriate hydrocarbon gas and/or hydrogen adsorbing materials. Optionally, each briquette unit includes a wrapper for preventing circulation of said particulate matter within the storage tank. Optionally, the storage system includes a mechanism for supplying or removing heat to at least one briquette unit. Furthermore, a method for manufacturing any of the aforementioned gas storage systems is disclosed. Some embodiments of the present invention provide methane-powered motor vehicles including but not limited to automobiles, buses, trucks and ships including a storage system with compressed methane-adsorbing particulate matter. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a system for connecting a flowline to subsea hardware, and more particularly for remotely connecting a flowline to a wellhead connection or other subsea structure.
2. Brief Description of the Related Art
Flowlines used to connect subsea well completions or subsea manifolds to a production facility are generally deployed to the seafloor independently of other hardware. During the well tie-in phase the flowlines must be pulled from their laydown position to the subsea tree and then connected to the tree. This operation has traditionally been accomplished by divers using a combination of rigging and gantries on the subsea structure, although in deeper water a number of diverless connections have been achieved.
There are three main methods for performing a diverless flowline connection as follows:
(1) Surface Connection/Lay Away
The flowlines are passed from the lay vessel to the drill rig and connected to the tree on the surface, and leak tested. The tree is then "run" down the guidewires and established on the wellhead. The lay vessel lays the flowline away from the tree allowing the other end of the flowline to be connected on the surface.
(2) Subsea Connection/Lay Away
The tree is established on the wellhead by the drill rig. The flowlines are passed from the lay vessel to the drill rig. The flowline ends are then run down guide wires on the tree to align the pipe flange with the tree flowline connection hubs. A flowline connection running tool is then deployed down the guidewires and operated hydraulically to perform the connection subsea.
(3) Laydown/Subsea Connection
Remote pull-in and connection methods are used to complete the flowline connection. This is generally performed after the flowline has been laid on the seabed.
Methods (1) and (2) have a reasonable track record, however, they both suffer the disadvantage of relying upon the drillship and flowline lay vessel being in position in the field at the same time. For multiple well developments this is generally a cost exposure that is uneconomical. Method (2) also requires a large equipment/support area on the subsea structure which complicates the design and increases costs.
In method (3) the flowline is first laid on the seabed to within a short distance, typically to within fifty meters of the wellhead, and then the end of the flowline is pulled along the seabed and engaged to the wellhead connection. The flowline, although flexible, is relatively rigid at the end thereof. Thus, it is necessary that the end of the flowline be brought into proximity with the wellhead connection at the correct angle so that accurate engagement can take place.
Australian Patent Application Serial No. 28509/92 titled "Flowline Connection System," published May 20, 1993, discloses a module for connection to a remotely operated vehicle (ROV). The module attaches to the end of the flowline in a predetermined direction. A single winch system is mounted to the module and includes a winch line for attachment to the wellhead connector so that as the winch pulls in the winch line, the module is pulled towards the wellhead. The module includes a lateral thruster to laterally adjust the position of the module.
It is desirable to have a diverless flowline connection system adapted for use by either mounting the apparatus to the flowline and pulling the flowline to the connector or attaching the apparatus to the subsea manifold/template and winching the flowline to the connector. It is also desirable to have a winching system which allows for a balanced pull force through the centerline of the flowline and which will not put a moment on the flowline during final pull-in. Additionally, it is desirable to have a winch system which permits controlled application of a moment on the flowline to assist in the alignment of the flowline with the connector on the manifold/template. It is also desirable that the apparatus be modular to accommodate various flowline diameters, be light-weight, and include automatic release mechanisms upon power failure.
SUMMARY OF THE INVENTION
The diverless flowline connection system (DFCS) is a specialized remotely operated tool for connection of submerged flowlines to a subsea structure, as for example a wellhead or template. The DFCS can be used in two operational tie-in configurations: 1) pull from flowline end, or 2) pull from subsea structure.
The DFCS includes a skid frame for containing a pair of winches, at least two pair of flowline clamp arms, winch line guillotines and pinch rollers, a damper/alignment assembly and a hydraulic manifold.
The DFCS is modularly constructed to provide flexibility to pull-in a variety of different flowline sizes.
The DFCS includes a dual winch system which allows for a balanced pull force through the center of the flowline which will not put a moment on the flowline during final pull-in. The dual winch system includes independent controls of the winches to permit controlled application of a moment on the flowline to assist in the alignment of the flowline with the connector on the wellhead or subsea structure. This allows the DFCS to laterally adjust the position of the flowline and the DFCS as it approaches.
The DFCS utilizes the ROV hydraulic power unit with only hydraulic hoses as the power/control interface between the ROV and the DFCS. By using the ROV hydraulics, the DFCS avoids the extra weight of a second hydraulic power unit. The less weight on the DFCS skid avoids additional buoyancy requirements and improves the maneuverability of the ROV when attached to the DFCS.
The DFCS also includes release mechanisms to release the DFCS from the flowline and subsea structure in the event of power failure. One release mechanism is the winch line guillotine which severs the winch line in the event of power failure. Another release mechanism releases the grip of the clamp arms in the event of power failure.
BRIEF DESCRIPTION OF THE DRAWINGS
A better understanding of the invention can be had when the following detailed description of the preferred embodiment is considered in conjunction with the following drawings, in which:
FIG. 1 is a side elevational view of the module of the diverless flowline connection system (DFCS) according to the present invention attached to a remotely operated vehicle;
FIG. 2 is a top plan view of the DFCS module;
FIGS. 3-5 are end elevational views of the DFCS module, showing the modular design of the DFCS module to accommodate various flowline diameters;
FIG. 6 is an end elevational view of the clamp arm assembly;
FIG. 7 is an elevational view of the winch line guillotine and pinch roller assembly;
FIG. 8 is a view taken along line 8--8 of FIG. 7;
FIG. 9 is a diagrammatic view showing the ROV with the DFCS module docking the stab in anchors to the manifold;
FIG. 10 is a diagrammatic view showing the ROV flying to the flowline while paying out the DFCS winch lines;
FIG. 11 is a diagrammatic view showing the DFCS clamping onto the flowline;
FIG. 12 is a diagrammatic view showing the ROV with DFCS and flowline pulling-in to the connector by reeling in the DFCS winch lines;
FIG. 13 is a diagrammatic view showing the final make-up of the flowline into the connector; and
FIGS. 14-16 are diagrammatic views showing a vertically deployed flowline being pulled in from a subsea structure.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIGS. 1 and 2, the diverless flowline connection system (DFCS), designated generally as 20, includes a modular skid frame assembly 22. Preferably, the modular skid frame assembly 22 is assembled from tubular members t for buoyancy considerations as will be explained below.
Referring to FIGS. 2-5, the skid frame assembly 22 is modular and comprised of a pair of outer frames, individually referred to as 24 and 25, joined to a plurality of center pup assemblies 26. The outer frames 24 and 25 are mirror images of one another. The pup assemblies 26' (FIG. 3), 26" (FIG. 4) and 26"' (FIG. 5) are designed to accommodate various ranges of flowline diameters. For example, pup assembly 26' may be designed for diameters ranging from 2"-12", pup assembly 26" for diameters ranging from 8"-18", and pup assembly 26"' for diameters ranging from 12"-20". The pup assemblies 26 are simply removed and replaced by removing a plurality of bolts 26a (FIG. 2). Since flowline size varies for each different subsea development, the modular design provides increased capability of being used on a large number of subsea developments.
As shown in FIG. 2, a plurality of pup assemblies 26 are used to join the outer frames 24 and 25. In the preferred embodiment as shown in FIG. 2, four pup assemblies 26 are required. Referring to FIGS. 3-5, the pup assemblies 26 include an upper saddle 28 for receiving the upper portion of the flowline F. Each saddle 28 is sized according to the range of diameters it is to accommodate. Similarly, the width of the pup assemblies 26 increases as the flowline diameters increase. It is to be appreciated that the overall width of the skid frame assembly 22 is kept to a minimum based on the diameter of the flowline F as a result of the modular design. This results in improved handling and maneuverability of the DFCS 20.
Referring to FIG. 6, a pair of clamp arms 30 are mounted on pivot pins 32. The pair of clamp arms 30 are hydraulically actuated and have a hydraulic cylinder 33 pivotally connected between the upper ends 31 of the clamp arms 30. As shown in FIG. 6, the clamp arms are allowed to move through an arc 35 about the pivot pins 32. The clamp arms 30 enable the DFCS 20 to clamp onto the end of the flowline F or onto the structure of the wellhead. The clamp arms 30 allow the DFCS 20 to be vertically lowered onto the flowline F. Once the DFCS 20 is positioned onto the flowline F, the hydraulics are activated to pivot the clamp arms 30 until they grippingly engage the flowline F. The clamp arms 30 extend low enough to enable the clamp arms 30 to lift the flowline F out of the mud or sand, if necessary. In the event of hydraulic system failure, the clamp arms 30 can be activated to release the flowline F. For example, if the hydraulics are lost on the ROV, the hydraulic circuit to the clamp arms 30 is opened to vent back into a hydraulic tank (not shown) which allows the clamp arms 30 to release the flowline F.
Referring to FIGS. 3 and 4, the outer frames 24 and 25 each include the pivotal clamp arms 30 mounted on the pivot pins 32. In FIG. 5, the pup assembly 26"' includes pivotal clamp arms 30' which rotate about pivot pins 32'. The clamp arms 30 have been removed from the outer frames 24 and 25. The clamp arms 30' are hydraulically actuated and function as the clamp arms 30 described above.
Preferably, the outer frames 24 and 25 and the pup assemblies 26 are assembled from tubular members t which are water-tight to provide the modular skid frame assembly 22 with supplemental buoyancy. Preferably, isolation compartments (not shown) are formed within the tubular members t to minimize the loss of buoyancy should any tubular member t flood. Although not shown, the DFCS 20 also includes buoyant foam attached to the skid frame assembly 22 to provide the DFCS with a net overall positive buoyancy.
Referring to FIGS. 1-5, wood and/or rubber bumpers 34 are attached to the perimeter and underside of the skid frame assembly 22 to prevent damage to the tubular members t.
Referring to FIGS. 1 and 2, the DFCS 20 includes a pair of winches 36 attached to a pair of stab-in anchors 38. The winches 36 are on opposed sides of the flowline F in a horizontal plane. The winches 36 are subsea winches and each winch 36 is independently controlled. Preferably, the winches 36 each have a full-drum pull capacity of approximately 5 metric tons and a maximum line speed of approximately 0.15 m/sec. Preferably, the maximum usable capacity of the winch 36 is in excess of 60 meters. The winch line 36a (FIG. 10) is preferably light-weight. In the preferred embodiment, the winch line 36a is a soft kevlar line for reasons which will be explained below.
It is to be understood that the ROV is controlled from the water surface, as for example from a floating vessel, and the various ROV controls are well known to one of ordinary skill in the art. As explained above, the DFCS 20 utilizes the ROV hydraulic power unit with only hydraulic hoses as the power/control interface between the ROV and the DFCS 20. Thus, the hydraulics of the DFCS 20 are controlled through the ROV controls.
The stab-in anchors 38 enable final alignment of the flowline F and to connect the winch lines 36a to the receptacles located either side of the connector or the pull-in head (depending on the tie-in method as will be described below). The ends of the winch lines 36a are connected to the stab-in anchors 38. The stab-in anchors 38 can be removed by an ROV manipulator in the event of a DFCS failure.
Referring to FIGS. 1 and 2, a damper/alignment assembly 80 is provided at the front end of the DFCS 20. The damper/alignment assembly 80 includes slide tubes 82 mounted in the outer frames 24 and 25. The slide tubes 82 are allowed to travel a distance of approximately 12 inches forward of the outer frames 24, 25 as shown in FIGS. 9-12. The slide tubes 82 are hydraulically actuated. The slide tubes are adapted interiorly to receive and lock with a mating portion 38a (FIG. 11) of the stab-in anchor 38. The locking of the stab-in anchor 38 with the slide tube 82 is hydraulically controlled.
Referring to FIGS. 1, 2, 7 and 8, the DFCS 20 includes winch line guillotines 40 and pinch rollers 42. The DFCS 20 incorporates guillotines 40 on the two winch lines 36a as a contingency against loss of system power. An accumulator (not shown) is included in the hydraulic system for the guillotines 40. The accumulator stays charged under normal hydraulic pressure operating conditions. In the event of loss of system power, the accumulator activates a hydraulic ram (not shown) which forces a guillotine blade 41 through the winch line 36a and against an anvil (not shown). In this event, the two winch lines 36a will be cut leaving the DFCS 20 free to be recovered. This, coupled with the release of the clamp arms 30, allows the DFCS 20 to be simply removed from the flowline F in case of ROV hydraulic system failure by lifting the DFCS 20 or DFCS 20 and ROV assembly using a separate lifting source.
Referring to FIG. 7, each winch line 36a passes through a pair of pinch rollers 42 that maintain a small tension on the winch line 36a to/from the winch 36. This feature prevents "birdcaging" of the winch line 36a in the event of the winch line 36a going slack during ROV/DFCS free-flying maneuvers. The tension is maintained whether line is being payed out or reeled in.
As indicated above, the winch line 36a is preferably a soft kevlar line to minimize weight, allow the use of the constant tension pinch rollers 42, and to allow severance by the failsafe guillotine 40.
The DFCS 20 includes a hydraulic system which utilizes the ROV hydraulic power and control valves, and therefore only requires hydraulic connection between the ROV and DFCS 20 for full function. Preferably, the hydraulic connection between the ROV and DFCS 20 is performed with the aid of a 16-port hydraulic hot stab (not shown). A 16-port hydraulic hot stab is commonly used with an ROV and is well known by one skilled in the art. The multi-port hot stab is connected to the DFCS 20 by the ROV manipulator. The hot stab requires no insertion force and permits such limited amounts of water ingress that no intermediate system is required to isolate the ROV hydraulic supply from the multi-port hot stab.
Preferably, the mechanical connection between the ROV and the DFCS is made by the use of a docking probe assembly 60 as shown in FIG. 1. The docking probe assembly 60 includes a receiver 62 located substantially midway between the outer frames 24 and 25 at the front end of the DFCS 20. The docking probe receiver 62 includes a tubular housing 64 having an inwardly tapering first end 64a and a generally peripheral flange 66 with a plurality of holes (not shown) for bolting the receiver 62 to a receiver plate 68. The receiver plate 68 is secured to the front pup assembly 26. The tubular housing 64 includes a pair of opposing slots 64b having a slight outward taper. A plug member 72 adapted to mate with the docking probe receiver 62 is mounted to the front end of the ROV.
Referring to FIG. 1, a rear stanchion 70 extends upwardly from the rear portion of the DFCS 20. As stated above, the DFCS 20 has a positive buoyancy. When the ROV mounts to the docking probe receiver 62 at the front end of the DFCS 20, the rear stanchion 70 bears against a lower surface of the ROV due to the positive buoyancy of the DFCS 20.
The docking probe assembly, in conjunction with the multi-port hot stab, enables the ROV to separate from the DFCS to perform any required ancillary or contingency operations without the need for a second ROV. Preferably, failsafe hydraulics are provided to allow for the separation of the ROV from the DFCS 20 in the event of vehicle failure.
Referring to FIGS. 9-13, the basic operational sequence for pulling from the flowline end towards the wellhead connection is described as follows. First, the flowline F is placed on the seabed within a fixed distance of the wellhead connection C.
The ROV with the DFCS 20 mounted thereto flies to the connection C and stabs the DFCS stab-in anchors 38 into female receptacles mounted on either side of the connection C. This action anchors the ends of the two DFCS winch lines 36a to the subsea wellhead W. Referring to FIG. 10, the ROV activates the DFCS winches 36 to pay out the winch lines 36a as the ROV flies backward toward the flowline F. Referring to FIG. 11, the ROV lands the DFCS 20 over the flowline F and activates the clamp arms 30. This locks the DFCS 20 and ROV onto the flowline F. The winches 36 are activated to commence pulling the flowline F up to the subsea wellhead W. The dual winch system and the independent controls of the DFCS 20 permit controlled application of a moment on the flowline to assist in the alignment of the flowline F with the connector C on the wellhead or subsea structure W. This allows the DFCS 20 to laterally adjust the position of the flowline and the DFCS 20 as it approaches the wellhead W. This lateral movement is in addition to that which can be supplied using the thrusters on the ROV.
The DFCS winches 36 continue to pull the flowline F up to the wellhead connection C until the flowline F is approximately 300 millimeters from the connector C. The final 300 millimeters of pull-in is performed with the winches and hydraulic damper/alignment assemblies. This provides a control method of aligning the flowline hub as it enters the connector, minimizing potential damage of the hub and flange faces.
The dual winch system of the DFCS 20 allows for a balanced pull force through the center of the flowline F which will not put a moment on the flowline F during final pull-in, as the winches 36 are substantially vertically aligned with the center of the flowline F and the winches 36 are controlled during the final pull-in to provide no horizontal moment. The locking of the stab-in anchors 38 with the damper/alignment assemblies 80 allows the final pulling in of the flowline F to be performed hydraulically by retrieving the sliding tubes 82 back to their retracted positions.
It is to be understood that in the method described above (pull from flowline end), the DFCS 20 is an integral part of the ROV throughout the complete pull-in operation.
In the method of pulling the flowline F from the subsea structure W, the ROV locates the DFCS 20 onto a part of the wellhead structure W and pulls the flowline F in from this position. There are two variations to this arrangement: (1) the flowline F is lowered vertically (FIG. 14) from the support vessel (not shown), tied in and then laid away, or (2) the flowline F is first laid on the seafloor and then the connection is made.
Referring to FIGS. 14-16, the basic operational sequence is as follows. The DFCS 20 is lowered in a deployment frame/equipment basket (not shown) to the seafloor. The ROV docks onto the DFCS 20 and transports it to its operating position on the subsea structure W. Referring to FIG. 14, a flowline pull-in head 50 is mounted on the end of the flowline F. The pull-in head 50 provides a means to connect the stab-in anchors 38 to the end of the flowline F and guides to assist in the final alignment of the flowline at the subsea structure W. Referring to FIG. 14, the flowline F and the pull-in head 50 are vertically lowered to the target zone at the seafloor (approximately 60 meters from the subsea structure W) and held for the DFCS winch lines 36a to be connected to it.
The ROV undocks from the DFCS 20 and with the ROV manipulator, takes the stab-in anchors 38 from their socket on the DFCS 20. The stab-in anchors 38 with attached winch lines 36a are flown and docked to a socket 52 held by the flowline pull-in head 50.
The ROV flies back to the DFCS 20 and redocks onto it, using its multi-port hot stab to operate the DFCS hydraulic functions. The ROV powers the DFCS winches 36 to pull the flowline F in until it rests on the pull-in ramp. The flowline is pulled in until the flanges are fully made up, confirmed visually by a micro camera (not shown) mounted to the manipulator forearm.
The pull from subsea structure configuration has the following benefits over the pull from flowline end configuration. In the pull from subsea structure configuration, the DFCS 20 is not an integral part of the ROV. Without the excess bulk of the DFCS 20 the ROV can be easily maneuvered and can readily attend to other work tasks as required. In the pull from flowline end configuration, the flowline can be manipulated and pulled on by each or both of the winches 36 resulting in the ability to pull in various directions. If necessary, the side thrusters of the ROV can also be utilized to alter the direction force on the flowline. Thus, in this configuration, better angular control of the flowline is available.
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 without departing from the spirit of the invention. | A diverless flowline connection system for connecting a flowline to a subsea wellhead or other subsea structure. The diverless flowline connection system is used with a remotely operated vehicle. The diverless flowline connection system includes a frame assembly including clamping arms for mounting the frame assembly to the flowline. A pair of winches are mounted to the frame assembly. Each winch includes a winch line for attachment to the wellhead to which the flowline is to be connected. Each winch is independently controlled so that the lateral position of the flowline may be variously adjusted by controlling each of the winches. The diverless flowline connection system is of modular design to accommodate a wide variety of flowline diameters. The connection system can also be used to pull from the wellhead. Winch line guillotines are provided for severing the winch lines and the clamping arms release the flowline in the event of hydraulic system failure. | 4 |
REFERENCE CITED
[0001] 1. U.S. Pat. No. 5,877,977
[0002] 2. U.S. Pat. No. 3,384,433
[0003] 3. U.S. Pat. No. 5,193,023
[0004] 4. U.S. Pat. No. 5,526,173
[0005] 5. U.S. Pat. No. 6,195,196
[0006] 6. U.S. Pat. No. 6,211,999
[0007] 7. U.S. Pat. No. 5,568,308
[0008] 8. U.S. Pat. No. 6,295,159
[0009] 9. U.S. Pat. No. 5,800,767
[0010] 10. U.S. Pat. No. 6,156,255
FIELD OF THE INVENTION
[0011] The present invention relates to a Method of fabricating two-dimensional ferroelectric nonlinear crystals with periodically inverted domains, particularly to domain inversion of ferroelectric nonlinear crystals with pulse field poling the nucleation site and transverse motion of inverted domains and two-dimensional nonlinear photonic crystals for time-domain multiple-wave simultaneous lasers and space filter. Therefore, this invention can be employed space-charge effect for screened fringing field beneath the metal electrode and constraint of inverted domain nucleation site in the oxidized electrode for arbitrarily geometrical form of two-dimension ferroelectric lattice structure.
BACKGROUND OF THE INVENTION
[0012] The physical feature for ferroelectric crystal is the spontaneous polarization (P s ), and the ferroelectric domain to reverse its spontaneous polarization (P s ). It offers an alternative 180° inversion, i.e., so-called domain inversion, and the capability to apply an electric field across the polar axis to overcome the coercive field (E c )in ferroelectric. One such example takes advantage of the reversible polarization and fast switching time to realize high-density memory devices for data storage, such as: S. Essaian “Nonvolatile memory based on metal-ferroelectric-metal-insulator semiconductor structure” U.S. Pat. No. 5,899,977 and O. Auciello et al. “The physics of ferroelectric memories”, Physics Today, pp. 22-27, July, 1998.
[0013] In ferroelectric nonlinear crystals, the 180° change in the spontaneous polarization (P s ) offer optics nonlinear coefficient of odd-order physical tensor by sign change Based on the following of: N. Bloembergen, U.S. Pat. No. 3,384,433 and “Interactions between light waves in a nonlinear dielectric”, Phys. Rev. vol. 127, pp. 1918-1939, 1982, offer a wave front vector K=2π/Λ approach by compensating effect of dispersion for the coefficient of refraction to overcome a phase-matching problem (kt −2k ≠0) when frequency transformation and satisfy the use of a Quasi-Phase-Matching (QPM) technique as shown in FIG. 1 with the relatively physical structure to satisfy kt −2k ≠0 and length of per inverted domain with Λ=2l c at l c =λ/4(n 2 −n ).
[0014] As mentioned above, M. Yamada et al. U.S. Pat. No. 5,193,023, “Method of controlling the domain of a nonlinear ferroelectric optics substrate”, and “The first-order quasiphase-matched LiNbO 3 waveguide periodically poled by applying an external field for efficient blue second-harmonic generation,” in Appl. Phys. Lett. Vol. 62, pp. 435-436, 1993, that discloses a short pulse voltage is applied QPM structure of periodically poled lithium niobate (PPLN) for second-harmonic-generation (SHG) green laser. Y. Kitaoka et al., “Miniaturized blue laser using second harmonic generation”, in Jpn. J. Appl. Phys. Vol. 39, pp. 3416-3418, 2000, that discloses the tiny QPM-SHG blue-laser technique such as 5×12×1.5 mm 3 . Using the 20 mW-infrared semiconductor laser as the pumping source, the power of blue laser transformation is 2 mW.
[0015] The summary of technique problems for applying to QPM inverted domain structure comprises the item of.
[0016] (1). the situation becomes complicated on fabricating of small periodical inverted-domain structure due to the existence domain merge in the polarization switching process.
[0017] (2). improved the separation of fundamental frequency and frequency transformation light such as the same polarization direction and parallel each other to propagate the light.
[0018] As discussed herein, the first problem reason belong to fringing field effect due to a large dielectric discontinuity underneath the electrode pattern. As shown in FIG. 2(A) of a conventional poling configuration of z-directional poling diverted voltage for normal field (E z ) enhanced current spreading in the unpatterned regime, which is normally coated with a layer of insulating material. The distribution of switching current and charged field play an important role in determining the arrangement of the reversed domains. Therefore, an external supply of the switching current, i.e., 2 AdP s /dt serves to compensate the depolarization field in the newly switching area A. According to analysis of static electricity as shown in FIG. 2(B) of a conventional poling configuration of z-directional poling diverted voltage, a relatively large non-isotropy E x ˜ 4 E c can exist underneath the insulating layer. E x is its field line pointing to an inward direction from both sides underneath the insulating layer for unnecessary inverted domian. This phenomenon shows to result in field screening and compensating in the unpatterned regime to bring up the issue of domain broadinging, and deviates the QPM condition formed on its lattice structure for low efficiency of nonlinear optical transformation.
[0019] In addition, the reason of problem ( 2 ) is due to the QPM condition limit wave frequecy transformation to the wave collinear incidence for in FIG. 1. Because the wave front of the structure with periodical diverted domain parallel the said wave collinear incidence, the fundamental wave, wave of transformaton, and wave front of the structure with periodical diverted domain paralleling each other can not distingu distinguish one from the others. Therefore, the conventional QPM device must take another filter to divide into the fundamental wave and wave of transformaton that caused great inconvenience.
[0020] Other the conventional problems are proposed as follows:
[0021] (1). The insulating layer in FIG. 3, it is to restrain the domain necleation and motion in a subsequent field poling process for fringing field of ferroelectric nonlinear crystals covered by periodical metal eletrode for inverted domain.
[0022] First, the SiO 2 material is applied at the isolating layer as shown in K. Mizuuchi et al., “Generation of ultraviolet light by frequency doubling of a red laser diode in a first-order periodically poled bulk LiTaO 3 ”, Appl. Phys. Let. Vol. 70, pp. 1201-1203,1997.
[0023] Next, the Ta 2 O 5 , WO 3 , H f O 3 material is applied at the isulating layer as shown in M. C. Gupta et al., “Method of inverting ferroelectric domains by application of controlled electric field”, U.S. Pat. No, 5,750,283.
[0024] Subsequenctly, the spin-on-glass material is applied at the insulating layer as shown in G. D. Miller et al., “42%-efficient single-pass cw second-harmonic generation in periodically poled LiNbO 3 ”, Opt. Lett. Vol. 22, pp. 1834-1836. 1997.
[0025] As mentioned above, the Appl. Phys. Lett. Vol. 70, pp. 1201-1203,1997 issue can be related to fringing field enchanced current spreading (W min ) in the unpatterned regime, which is normally coated with a layer of insulating material such as SiO 2 . the experienced form between W min and substrate thickness (T) is W min =0.0027T−0.21 (μm).
[0026] Then, the W min =0.0027T−0.21 (μm) is subjected to through said substrate thickness (T) to decide to fabricate the accurate method of the least period. For example, the 500-μm-thick LiNbO 3 structure carry out together with the application of said substrate thickness (T) and the least error of the inverted domain erred from the path of metal eletrode pattern is 1.14 μm. In addition, the 850-nm-thick QPM-SHG structure can be fulfilled by periodical domain diversion at coherent length (l c ) l c =1.9 μm, then the substrate require lapping and polishing to become thin for the allowable error of QPM period.
[0027] Matsushita Electric Industrial Co.,Phys. Lett. Vol. 70, pp. 1201-1203 (1997)), that discloses the substrate such as LiTaO 3 require lapping and polishing to 150-μm thickness for fabricating the inverted domain with a 1.7 μm period in QPM structure.
[0028] Sony Corp.,Yamaguchi et al., “Method of local domain control on nonlinear optical materials”, U.S. Pat. No. 5,526,173, that discloses the substrate such as LiNbO 3 require lapping and polishing to 100-μm thickness.
[0029] On the other hand, the substrate such as LiTaO 3 and LiNbO 3 having hard coefficient above 5 scale can be dirctly stressed to the irregural diverted domain of end surface of ferroelectric nonlinear crystals using stress-induced piezoelectricity because of the substrate require lapping and polishing to become thin. As a result the pulsed field poling is inevitably controlled problem of periodcal inverted domain and yielding rate.
[0030] (2). The diffusion technique for controlling the inverted domain is to during the high-temperature treatment or chemical treatment using the lithium-ion difussion of the inner crystals because of local inverted domain Generally, the conventional techniques are proposed as follow: (a) titanium (Ti) diffusion, (b) proton exchange, (c) high-temperature lithium-ion out-difussion, (d) the oxide covered and heat treatment, such the (a) and (d) take place shallow surface domain inversion in the uncovered eletrode pattern regime and (b) take place shallow surface domain inversion in the uncovered metal pattern regime. The diffusion technique can support the big-area inverted domain using shallow surface domain inversion because of the temperature vs. time being exponential saturation. As the result the difussion technique is inevitably induced non-perpendicular boundary of inverted domain and changeable strauture and physical property.
[0031] S. Miyazawa, “Ferroelectric domain inversion in Ti-diffused LiNbO 3 optical waveguide,” J. Appl. Phys. Vol. 50, 4599-4903, 1979, that discloses the titanium (Ti)-diffusion technique.
[0032] M. L. Bortz et al., “Noncritical quasiphase-matched second harmonic generation in an annealed proton-exchange LiNbO 3 waveguide”, IEEE Quantum Electron. Vol. 30, pp. 2953-2960,1994, and K. Nakamura et al., “Antipolarity domain nucleation and growth during heat treatment of proton-exchanged LiTaO 3 ”, J. Appl. Phys. Vol. 73, p. 1390,1993, that discloses the proton-exchange technique.
[0033] K. Nakamura et al., “Ferroelectric domain inversion caused in LiNbO 3 plates by heat treatment”, Appl. Phys. Lett. Vol. 50, pp. 1413-1414,1987, that discloses the high-temperature lithium-ion out-difussion technique.
[0034] M. Fujimura et al., “Ferroelectric domain inversion induced by SiO 2 cladding for LiNbO 3 waveguide”, Elec. Lett. Vol. 27, pp. 1207-1209,1991, that disclosed the oxide covered such as SiO 2 and heat treatment.
[0035] C.-S. Lau et al., “Fabrication of MgO induced lithium out-diffusion waveguides,” IEEE Photon. Technol. Lett. Vol. 4, pp. 872-875,1992, that disclosed the oxide covered such as MgO and heat treatment.
[0036] As diffusion technique problems are proposed as follows:
[0037] 1. The difussion only with shallow surface domain inversion take place in a triangular pattern in the uncovered LiNbO 3 regime, and in a half-circle pattern in the uncovered LiTaO 3 regime, the inverted domain can not give the the idea perpendicular boundary that as shown in FIG. 1 and can give an unwanted influence to the nonlinear wave transformation.
[0038] K. Yamamoto et al., “Characteristics of periodically domain-inverted LiNbO 3 and LiTaO 3 waveguides for second harmonic generation”, J. Appl. Phys. Vol. 70, pp. 1947-1951,1991, that discloses the boundary of periodical inverted domain in contrast to transformation efficiency.
[0039] 2. The proton exchange cause the lattice composition and structure to form Li x H 1-x NbO 3 and decrease the coefficient of nonlinear optical transformation. The resultant substrate is subjected to heat treatment of annealing for decreasing effect of the mentioned above, but said coefficient of nonlinear optical transformation restores the limited degrees. Y. N. Korkishko et al., “The SHG-response of different phase in proton-exchanged lithium niobate waveguide”, IEEE J. Selected Topics in Quantum Electron. Vol, 6, pp. 132-142,2000, that discloses the proton exchange of the mentioned above.
[0040] (3). the decreasing coercive field (E c ) of the lump lattice to restrain the fringing field underneath the eletrode pattern. It can not change the optical nonlinear characteristic and transformation efficiency of the lattice, because of said decreasing coercive field (E c ) of the lump lattice reduces the defective density of lattices.
[0041] The conventional methods are proposed as follows;
[0042] 1. Stoichiometric nonlinear crystals offers composition of Li 2 O/(Nb 2 O 5 +Li 2 O) or Li 2 O/(Ta 2 O 5 +Li 2 O) for 0.49˜0.5 approach by substantially decreasing the coercive field to 2 kV/mm that is one tenth of congruent-grown crystals. V. Gopalan et al., “Lithium niobate single crystal and photo-functional device,” U.S. Pat. No. 6,195,196 and V, Gopalan et al., “Lithium tantalate single crystal and photo-functional device,” U.S. Pat. No. 6,211,999, that discloses the said stoichiometric nonlinear crystals.
[0043] 2. MgO or ZnO doping in congruent-grown crystals using the the material of atomic bond equivalent to LiNbO 3 or LiTaO 3 such as A. Harada, “Fabrication of ferroelectric domain reversal”, U.S. Pat. No. 5,568,308, that discloses the MgO doping in congruent-grown crystals, and L,-H. Peng et al., “Method for bulk periodic poling of congruent grown ferroelectric nonlinear optical crystals by low electric field”, U.S. Pat. No. 6,295,159, that discloses the ZnO doping in congruent-grown crystals.
[0044] When doping in congruent-grown lithium niobate (LiNbO 3 ) is Li 2 O/(Nb 2 O 5 +Li 2 O)=0.485 wherein the doping control into the consistency range of 3˜9 mol % for reducing lattice defects, the coercive field can effectively reduce one tenth of congruent-grown crystals and carry out the resistant-light destructiveness and resistant-light deflection.
[0045] As mentioned above, when doping in congruent-grown crystals for decreasing the coercive field, it must control the doping accuricy to overcome the induced law lattice quality for over doping and without compensated lattice defects for under doping.
[0046] (4). The pulsewave controlling offers the adjustment the field wave and duty cycle between the positive and negative electrode to shift the inverted domain such as: K. Mizuuchi et al., “Method for manufacturing domain-inverted region, optical wavelength conversion device utilizing such domain-inverted region and method for fabricating such device”, U.S. Pat. No. 5,652,674 and R. G. Batchko et al., “Back-switching poling in lithium niobate for high-fidelity domain patterning and efficient blue light generation”, Applied Physics Letters, Vol. 75, pp. 1673-1775. Said the pulse-wave controlling must appropriate liquid eletrode in order to avoid the dielectric collapse of material. Such as: R. L. Byer et al., “Electrical field domain patterning,” U.S. Pat. No. 5,800,767 and U.S. Pat. No. 6,156,255.
SUMMARY OF THE INVENTION
[0047] The main object of present invention is to provide domain inversion of ferroelectric nonlinear crystals with field control the nucleation and transverse motion of inverted domains and two-dimensional nonlinear photonic crystals for time-domain multiple wave simultaneous lasers and space filter function,
[0048] Another object of present invention is to provide space-charge effect for screened fringing field beneath the metal electrode.
[0049] The other object of present invention is to provide the constraint of inverted domain nucleation in the oxidized electrode for arbitrarily geometrical form of two-dimension ferroelectric lattice structure.
[0050] In order to achieve foregoing objects, the present invention relates to a method of fabricating two-dimensional ferroelectric nonlinear crystals with periodically inverted domains, comprising the step of:
[0051] a) Forming a first metal electrode on nonlinear crystal;
[0052] b) Heat treatment thereof obtained according to a) at lower than Curie temperature;
[0053] c) Taking place first shallow surface domain inversion in thereof obtained according to b);
[0054] d) Forming a second metal electrode on thereof obtained according to c);
[0055] e) Applying a voltage higher than coercive field to thereof obtained according to d); and
[0056] f) Taking place second deep surface domain inversion in thereof obtained according to e).
BRIEF DESCRIPTION OF THE DRAWINGS
[0057] The present invention will be better understood from the following detailed description of preferred embodiments of the invention, taken in conjunction with the accompanying flow diagram, in which
[0058] [0058]FIG. 1 is a diagram showing quasi-phase-matching (QPM) periodically inverted domain structure and nonlinear frequency transformation,
[0059] FIGS. 2 (A) and (B) are diagrams showing normal field (E z ) and tangential field (E x ) distribution at various depths beneath the insulating layer according to conventional poling configuration;
[0060] [0060]FIG. 3 is a diagram showing tangential field (E x ) underneath a positively charged parabola intervening between the electrodes according to the present invention;
[0061] [0061]FIG. 4(A) is a diagram showing y face micrograph of a z-cut, 500-μm-thick PPLN-QPM structure with 20 μm period after the heat treatment at 1050° C. for 5 h according to the first embodiment of the present invention;
[0062] [0062]FIG. 4(B) is a diagram showing y face micrograph of a z-cut 500 μm-thickness PPLN-QPM structure with 20 μm period after the heat treatment at 1050° C. for 5 hour and followed up by a pulsed field poling according to the first embodiment of the present invention;
[0063] FIGS. 5 (A) and (B) are diagrams showing y face and -z cut micrograph of a z-face 500 μm-thick PPLN-QPM structure with 6.8 μm period according to the second embodiment of the present invention;
[0064] [0064]FIG. 5(C) is a diagram showing temperature-tuning curves of SHG power and the fitting result for using a 1064 nm Nd:YAG laser as the pumping source according to the second embodiment of the present invention;
[0065] [0065]FIG. 6(A) is a diagram showing 2D PPLN-QPM rectangle lattice structure according to the third embodiment of the present invention;
[0066] [0066]FIG. 6(B) is a diagram showing CCD image and intensity of far field pattern from the emission of arrayed 2D QPM-SHG pumped by a 1064 nm Nd:YAG laser of FIG. 6(A);
[0067] [0067]FIG. 6(C) is a diagram showing the different angles between fundamental frequency light and multiple lattice vectors of 2D PPLN-OPM rectangle lattice structure from the emission of arrayed 2D QPM-SHG pumped by a 1064 nm Nd:YAG laser according to the third embodiment of the present invention; and
[0068] [0068]FIG. 6(D) is a diagram showing the different direction between fundamental frequency photon and the emission of arrayed 2D QPM-SHG pumped by a 1064 nm Nd:YAG laser of 2D PPLN-QPM rectangle lattice structure for lattice component K i±1 with fine tuning ±1.5° the incident angle of fundamental frequency photon according to the third embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0069] The following descriptions of the preferred embodiments are provided to understand the features and the structures of the present invention.
[0070] [0070]FIG. 3 illustrates a spatial distribution of P s in the subsurface regime to restrain the domain nucleation and motion in a subsequent field poling process. The shallow surface domain inversion takes place in a triangular spatial distribution, whose thickness can be as deep as 5 μm. FIG. 4(A) illustrates the y face micrograph of an etched 20-μm-period quasi-phase-matching (QPM) structure after the first high-temperature treatment at 1050° C. for 5 h. FIG. 4(B) illustrates the etched y face micrograph of a periodically poled LiNbO 3 QPM structure that has undergone both the heat treatment and pulsed field poling. In comparison, the inverted triangular domains formed during the first heat treatment remain unchanged and stay outside the electrode regime after the pulsed field poling. The present invention is to disclose method of fabricating two-dimensional ferroelectric nonlinear crystals with periodically inverted domains, comprising the step of:
[0071] a). Form a first metal electrode on nonlinear crystal. The said crystal is selected from the group consisting of congruent-grown lithium niobate LiNbO 3 (Li x H 1-x NbO 3 ), congruent-grown lithium tantalate LiTaO 3 (Li x H 1-x TaO 3 ), zinc oxide doped congruent-grown lithium niobate (ZnO:LiNbO 3 ), magnesium oxide doped congruent-grown lithium niobate (MgO:LiNbO 3 ), stoichiometric LiNbO 3 , magnesium oxide doped stoichiometric LiNbO 3 , stoichiometric LiTaO 3 , and magnesium oxide doped stoichiometric LiTaO 3 . The said first metal electrode is selected from the group consisting of aluminum(Al), zinc(Zn), nickel(Ni), titanium(Ti), tantalum(Ta), gold(Au), chromium (Cr), silver(Ag), silicon (Si), germanium(Ge) or alloys thereof. The said first metal electrode is a one-dimension or two-dimension figure.
[0072] b). Heat treatment thereof obtain according to a) at lower than Curie temperature. The said heat treatment is in ambient oxygen.
[0073] c). Take place first shallow surface domain inversion in thereof obtained according to b). The said heat treatment at lower than Curie temperaturel is to take place first shallow surface domain inversion in said thereof obtained according to b) excluding said first metal electrode covered. The diffusion of said first shallow surface domain inversion is selected from the group consisting of Li out-diffusion by heat treatment, Ti-ion in-diffusion by heat treatment or proton exchange. The depth of said first shallow surface domain inversion is larger than 50 nm.
[0074] d) Form a second metal electrode on thereof obtained according to c) said second metal electrode is selected from the group consisting of aluminum(Al), zinc(Zn), nickel(Ni), titanium(Ti), tantalum(Ta), gold(Au), chromium (Cr), silver(Ag), silicon (Si), germanium(Ge) or alloys thereof. The pulsed field poling of said second deep surface domain inversion is applied voltage domain inversion with higher than coercive field of said crystal.
[0075] e) Apply a voltage higher than coercive field to thereof obtain according to d). And
[0076] f) Take place second deep surface domain inversion in thereof obtained according to e).
[0077] The first embodiment of present invention for process of fabricating one-dimensional ferroelectric nonlinear crystals with periodically inverted domains is proposed as follows:
[0078] In the first step, polarization switching was performed on 500-μm-thick, Z-cut congruent grown LiNbO 3 substrates purchased from Crystal Technology, USA. A thin (˜50 nm) aluminium (Al) electrode pattern (said first metal electrode) was evaporated onto the +Z face of LiNbO 3 using a standard lithography technique. In the next step, a typical procedure is to let the patterned sample be placed inside a quartz tube furnace and undergo heat treatment at 1050° C. for 5 h in an air ambience, and then take place said first shallow surface domain inversion. The electrode pattern of said first metal electrode is selected from the group consisting of evaporation or electron beam sputtering. As shown in FIG. 4(A) is the y-cut micrograph of an etched 20-μm-period PPLN-QPM structure with HF etching solution after the said heat treatment. Said first shallow surface domain inversion takes place in a triangular spatial distribution, whose thickness can be as deep as 5 μm. Said the first metal electrode can preserve the underlying LiNbO 3 domain in its original polarization state.
[0079] After the said heat treatment and then pulsed field poling, the first oxidized electrode was applied to a pulsed voltage at 12 KV and 20 ms for domain inversion as shown in FIG. 4(B) to the y-cut micrograph of PPLN-QPM structure. The new 180° periodically inverted domains is found to take place only underneath the oxidized electrode. That is, it Is the use of micro-porosity from the oxidized electrode to establish an electric contact and form nucleation sites of domain inversion. Furthermore, the second periodically inverted domains formed during pulsed voltage remain tangential to move and confined to the edge of triangular domain boundary formed during the said heat treatment. The thickness of said second periodically inverted is 500 μm to penetrate LiNbO 3 substrate. The FIG. 4(B) clarifies the use of positively charged barriers to inhibit the fringing field of tangential direction and to constrain the growth of domain inversion.
[0080] The second embodiment of present invention for process of fabricating one-dimensional ferroelectric nonlinear crystals with periodically inverted domains to small nominal period (less than 8 μm) is proposed as follows:
[0081] To fabricat the QPM-SHG inverted domains to small nominal period (less than 8 μm) on congruent-grown lithium niobate LiNbO 3 , the first metal electrode oxidizes during heat treatment at 1050° C. for 5 h in an air ambience, and then apply to a pulsed voltage at 12 KV and 10 ms for domain inversion. FIG. 5 show the etched micrograph of the (A) y, and (B) −Z faces of a QPM-SHG structure with a nominal 6.8 μm period on 500-μm-thick congruent-grown lithium niobate LINbO 3 with HF etching solution. Because of switching 180° periodically inverted domains have the different etching rates for HF etching solution, the FIG. 5(A) and FIG. 5(B) alternate with black and white stripe. FIG. 5(C) shows the operational temperature for the second-harmonic-generation (SHG) green light to use a 1064 nm YAG laser. The peak value of the frequency transformation meets at 100° C. to proof the OPM-SHG physical mechanism and half-height width of spectral regime reaches a efficacious lattice structural length of 2.3 mm. The framework of experiment in FIG. 1, the x-directional of QPM-SHG structure transfer the fundamental frequency and SHG green light, furthermore, it need the filter to split the SHG green light.
[0082] [0082]FIG. 6(A) shows 2D PPLN-QPM rectangle lattice structure. FIG. 6(B) shows CCD image and intensity of near field pattern from the emission of arrayed 2D QPM-SHG pumped by a 1064 nm Nd:YAG laser of FIG. 6(A). FIG. 6(C) shows the different angles between fundamental frequency light and multiple lattice vectors of 2D PPLN-QPM rectangle lattice structure from the emission of arrayed 2D QPM-SHG pumped by a 1064 nm Nd:YAG laser according to the third embodiment of the present invention. FIG. 6(D) is a diagram showing the different direction between fundamental frequency photon and the emission of arrayed 2D QPM-SHG pumped by a 1064 nm Nd:YAG laser of 2D PPLN-QPM rectangle lattice structure for lattice component K i±1 with fine tuning ±1.5° the incident angle of fundamental frequency photon.
[0083] The third embodiment of present invention for process of fabricating two-dimensional ferroelectric nonlinear crystals with periodically inverted domains is proposed as follows:
[0084] To fabricat the two-dimensional ferroelectric nonlinear crystals with periodically inverted domains on 500-μm-thick congruent-grown lithium niobate LiNbO 3 substrates, the first metal electrode oxidizes and transforms into a pattern during heat treatment at 1050° C. for 5 h in an air ambience. The said first metal electrode is a one-dimentional electrode pattern or two-dimensional pattern. In the uncovered LiNbO 3 regime takes palce said shallow surface domain, another It can preserve the inderlying LiNbO 3 domain in positively charged domain boundary. The next apply a pulsed voltage at 12 KV to said second metal eletrode for domain inversion. If the first metal eletrode is a one-dimentional pattern, the second metal eletrode places on the first oxidized eletrode to form the two-dimentional pattern. It is the use of micro-porosity from the oxidized electrode to establish an electric contact and form nucleation sites of domain inversion for LiNbO 3 regime. If the first metal eletrode is a two-dimentional pattern, it can apply the electrolyte to use of micro-porosity from the oxidized electrode to establish an electric contact and form nucleation sites of domain inversion for LiNbO 3 regime. FIG. 6(A) shows 2D PPLN-QPM rectangle lattice structure with periodicity of 6.8×13.2 μm 2 .
[0085] The 2D QPMSHG structure apply to use a 1084 nm YAG laser as second-harmonic-generation transformation approach to show 2D lattice structure with cylinder-like domain pattern whose periodically is 6.8×13.2 μm 2 in FIG. 6(A). In the above embodement, the y-directional of 2D-QPM structure with 13.2 μm period supports the deflection of the x-directional of 2D-QPM structure with 6.8 μm period by wave front vector to generate YAG light. Such a function is to space wave filter for fundamental frequency light. Because of the second embodiment is x-directional of 1D-QPM structure with small period to generate QPM-SHG light for parallel, it need the filter to split.
[0086] [0086]FIG. 6(B) shows CCD image and Intensity of near field pattern from the emission of arrayed 2D QPM-SHG green laser with periodicity of 6.8×13.2 m 2 . The theory analysis of space refraction effect response to the different lattice vector K mn for arrayed green laser as show in FIG. 6(C). it is can use y-directional nonlinear raster by deflection lattice vector K mn to match angle and intensity of SHG green laser. Because of y-directional level symmetry of the 2D structure, it has special corresponding angle in pairs between the lattice vector K mn to match SHG green laser and y axis. The 1D QPM structure with periodicity of 6.8 μm in FIG. 6(B), the emission of K 1.0 SHG green laser with corresponding angle of 0° to Y axis overlap the fundamental frequency YAG laser by parallel. FIG. 6(D) show operational temperature curve of the arrayed green laser. Applying the phase-matching high-order harmonic generation green laser to the y-directional raster can change the operational temperature from 8° C. to 80° C. that compare to the same-long 2D QPM structure in FIG. 6.
[0087] To sum up the above mentioned, the present invention is inventive, Innovative and progressive. The patent for this present invention is hereby applied for. It should include all variations and versions covered by the present invention, including possible minor improvements and more exact definitions
[0088] The above mentioned practical examples are used to describe the invention in more detail, they should therefore be included in the range of the invention, but should not restrict the invention in any way. | The present invention relates to a method to control the nucleation and transverse motion of 180° inverted domains in ferroelectric nonlinear crystals. It includes a process composing of a high temperature oxidation of the first metal layer and a pulsed field poling of the second electrodes. The main object of present invention is to provide domain inversion of ferroelectric nonlinear crystals with field control the nucleation and transverse motion of inverted domains and two-dimension nonlinear photonic crystals for time-domain multiple-wave simultaneous lasers and space filter function. Another object of present invention is to provide space-charge effect for screened edge field beneath the metal electrode, The other object of present invention is to provide the constraint of inverted domain nucleation in the oxidized electrode for arbitrarily geometrical form of 2D ferroelectric lattice structure. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to intruder alarm systems of the type used to detect mechanical vibrations in a security fence or the like and to generate an alarm signal accordingly. A serious problem arises in such systems owing to the difficulty of discriminating between vibrations arising from interference with the security fence by a would-be intruder and vibrations arising naturally e.g. from wind.
2. Description of Related Art
Various discriminator circuits have been designed in order to distinguish between spurious and genuine intruder signals. One such circuit is disclosed in U.K. Pat. No. 2,045,494B and has been found to be effective. However there exists a continuing need for improved signal processing techniques based on an improved knowledge of the signal, so as to discriminate more reliably between processed signal patterns arising from intrusion attempts and those arising from environmental sources such as wind, birds and other small animals. In particular it has been difficult to detect intrusion attempts when high winds act on the security fence.
SUMMARY OF THE INVENTION
According to the present invention an intruder alarm system for processing signals representative of vibrations in a security fence or the like comprises first means including envelope detector means for generating a peak amplitude signal responsive to the peak amplitude of said vibrations, further means responsive to said vibrations for generating a dynamic reference signal, said reference signal having a slow rise time, comparator means arranged to compare said peak amplitude signal with said dynamic reference signal and to generate an output signal, and means responsive to said output signal for generating an alarm indication.
Preferably said comparator means generates said output signal whenever the ratio of the peak amplitude signal to the dynamic reference signal exceeds a predetermined value. Said predetermined value is preferably between 3 and 4.5 times the value (typically unity) of said ratio under conditions of constant amplitude of said vibrations, and is most preferably approximately 3.5 times the value of said ratio under constant amplitude conditions.
Preferably the level of the dynamic reference signal is prevented from exceeding the level of the peak amplitude signal. This may be achieved by providing a discharge path for the dynamic reference signal to a terminal which is at the potential of the peak amplitude signal.
Preferably said first means includes integrating means with a rapid rise time and a decay time which is longer than the natural decay time of vibrations in the security fence and is desirably greater than 0.3 seconds, e.g. between 0.3 and 1.0 seconds.
The means responsive to the output signal may include timing means responsive to the persistence of said output signal for a predetermined period between 300 and 500 milliseconds to generate the alarm indication.
Preferably the rise time of said dynamic reference signal is greater than 1 second and is desirably between 3 seconds and 10 seconds--e.g. approximately 5 seconds. Preferably the decay time of said dynamic reference signal is significantly shorter than its rise time. Preferably the decay time of said dynamic reference signal is approximately equal to the decay time of said peak amplitude signal.
Preferably a threshold signal is continuously applied to the output of said further means so as to tend to inhibit said output signal when the amplitude of said vibrations is low. Otherwise even a very slight disturbance of the fence might cause the ratio of the peak amplitude signal to the dynamic reference signal to exceed the predetermined value. Preferably said threshold signal is applied to the outputs of both said further means and said envelope detector means, so that the signals applied to the inputs of the comparator means tend to equalise when the amplitude of said vibrations is low.
Preferably further detector means are provided to detect large fluctuations in the signals representative of said vibrations (arising, for example, from attempts to destroy the security fence) and to trigger an alarm signal accordingly.
BRIEF DESCRIPTION OF THE DRAWINGS
One embodiment of the invention will now be described by way of example only, with reference to FIGS. 1 to 3 of the accompanying drawings, of which:
FIG. 1 is a block diagram of an intruder alarm system,
FIG. 2 is a circuit diagram showing in more detail part of the intruder alarm system of FIG. 1,
FIG. 3(a) shows typical waveforms of the peak amplitude signal and dynamic reference signal generated in the circuit of FIG. 2,
FIG. 3(b) shows the corresponding ratio of these signals, and
FIG. 3(c) shows the corresponding "event" and "alarm" signals which occur in the circuit of FIG. 2 as a result.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, the intruder alarm system shown comprises a security fence 1 to which a plurality of geophones G are coupled. The outputs of the geophones are fed in series to the input terminals of a broadband amplifier 2 (which has a gain of 40 dB) which feeds a variable gain amplifier 3. Variable gain amplifier 3 can be adjusted during commissioning to vary the overall gain of the signal processing chain so as to set the sensitivity of the intruder alarm system to an appropriate level. The output of amplifier 3 is fed to a 1/3 octave bandpass filter 4(the centre frequency of this filter suitably being between 100 Hz and 250 Hz) and the filtered output is fed to an envelope detector 5 which feeds a D.C. output to the input of a unity-gain buffer 6. Envelope detector 5 incorporates an integrator with a fast rise time (e.g. of the order of a few milliseconds or less) and a slow decay time (i.e. significantly slower than the mechanical decay time of vibrations in the fence 1 and in this case 750 milliseconds). Thus the output of envelope detector 5 (and hence buffer 6) is essentially a unidirectional sawtooth waveform with rapidly rising leading edges and slowly decaying trailing edges. This waveform is fed directly via a resistive divider 8 and indirectly via a reference circuit 7 to respective inputs of a ratio comparator circuit 9. As will subsequently be described in detail with reference to FIG. 2, reference circuit 7 is driven by the peak amplitude signal and generates a unidirectional dynamic reference signal which has a slow rise time and a rapid decay time. Reference circuit 7 has a rise time of approximately 5 seconds and is provided with a unidirectional discharge path via an operational diode 17. This discharge path incorporates series-connected resistances R40 and R41 which are common to the discharge path of envelope detector 5 (and constitute the only resistance in its discharge path). Consequently the dynamic reference signal generated by reference circuit 7 decays at the same rate as the peak amplitude signal generated by envelope detector 5 whenever the peak amplitude signal falls to the level of the dynamic reference signal and continues to fall. This condition typically occurs at intervals of not more than a few seconds when the fence is under disturbance, so that the ratio of the peak amplitude signal to the dynamic reference signal is repeatedly returned towards unity irrespective of the general level of the peak amplitude signal. Voltage divider 8 and comparator circuit 9 are arranged so that comparator circuit 9 generates an output only when the instantaneous amplitude of the D.C. output signal from buffer 6 is at least 3.55 times as great as the instantaneous amplitude of the smoothed output from circuit 7 to the ratio comparator circuit 9. Hence the system as described thus far discriminates against signals from the geophones arising from continuous high winds acting on the fence 1, and also discriminates against varying signals arising from varying winds even though their amplitude builds up fairly quickly (i.e. over a period of a few seconds) because successive deep falls in the peak amplitude signal (which occur after each wind gust) reduce the duration of large ratios between the peak amplitude and dynamic reference signals during the build-up in wind. An equivalent build-up due to an intrusion attempt generally leads to a wider spacing between such deep falls in peak amplitude. Accordingly the duration of the output from comparator 9 is monitored in order to discriminate between these signal patterns. The output from comparator 9 is gated by a timer circuit 10 and a gate 11 so that gate 11 is activated only when the ratio of the input signal amplitudes at comparator 9 exceeds 3.55 for a period of between 300 and 500 milliseconds and, in this embodiment, 350 milliseconds. Wind-induced signals typically do not activate gate 11.
The output of gate 11 is fed to one input of a further gate 13. A further comparator circuit 12 feeds the other input of gate 13. Comparator circuit 12 and gate 13 preserve the integrity of the design against misguided use of too high a gain setting which could cause saturation of the envelope detector 5 in very high winds. Saturation of the envelope detector would tend to limit the ratio of the peak amplitude signal to the dynamic reference signal to too low a value. Accordingly comparator 12 is provided with a voltage reference V REF which corresponds to the onset of amplifier saturation, and gate 13 generates an output pulse (to trigger an alarm indication) if either of its inputs indicates a disturbance of the fence. A counter 14 is reset by this output pulse and generates an alarm signal for a pre-set period as a result. The duration of the alarm signal is governed by a timing oscillator 15 which also governs the timing circuit 10, as will subsequently be described with reference to FIG. 2.
Referring now to FIG. 2, envelope detector 5 incorporates an operational diode 16 (which acts as an ideal diode with no forward voltage drop) and an integrator comprising a 150 Ω resistor R38 and a 3.3 μF integrating capacitor C12. Series-connected resistances R40 and R41 provide a high resistance (220kΩ) discharge path for capacitor C12. Consequently the output of envelope detector 5 is a D.C. voltage corresponding to the peak amplitude of the signals from bandpass filter 4. with a decay time of approximately 750 milliseconds. This D.C. voltage is fed via a resistance R42 to a unity-gain buffer amplifier 6 and thence in parallel to averaging circuit 7 and voltage divider circuit 8. Averaging circuit 7 consists of a 3.3 μF capacitor C13 which is charged via a high (1.5MΩ) resistance R44 and (when the output of envelope detector 5 falls to the level of the dynamic reference signal from circuit 7) discharges through a low-resistance discharge path formed by a resistor R43, an operational diode 17 (which acts as a diode with no forward voltage drop) and resistors R42, R40 and R41. The effective resistance of this discharge path is essentially determined by R40 and R41 and is therefore the same as the resistance of the discharge path of envelope detector 5, namely 220kΩ. Consequently circuit 7 has a rise time of 5 seconds and (when the peak amplitude signal has fallen to the level of the dynamic reference signal) a decay time of approximately 750 milliseconds. Its output at the common terminal of R44 and C13 constitutes a reference voltage which is the first of the two signals compared in comparator circuit 9. Voltage divider 8 is composed of two resistors R45 and R46. The resistance ratio (R45+R46): R46 is set at 3.55. The instantaneous output of averaging circuit 7 is fed through a protective resistance R47 and compared with the output of voltage dividing circuit 8 by a differential amplifier 18 which is included in comparator circuit 9. Differential amplifier 18 generates a negative output whenever the output of voltage divider 8 (which corresponds to the waveform across integrating capacitor C12) exceeds the threshold voltage (which corresponds to the waveform across capacitor C13) by a factor of 3.55 or more. This negative output, fed through protective resistor R48 to one input of a NAND gate 19 (the other input being maintained at +5 V) causes NAND gate 19 to generate a positive EVENT pulse which persists as long as the critical 3.55 ratio is exceeded. The EVENT Pulse is differentiated by a differentiating capacitor C14 and resistor R51 and the resulting sharp pulse fed to a timing circuit 10 via a protective resistor R52. This sharp pulse triggers a negative reference pulse of known duration from the output of timing circuit 10 which is fed to one input of a NAND gate 11. Resistor R53 and capacitor C16 slow down the rise time of the EVENT pulse into one input of NAND gate 11, so that this input is still at logic low level when the negative reference pulse from timer 10 causes the other input of NAND gate 11 to fall to logic low level. The output of the gate therefore remains high during this transition. The input to gate 11 from counter 10 rises to logic high level at the end of the reference pulse, and if the EVENT Pulse still persists (i.e. the EVENT Pulse is longer than the reference pulse) then its output goes low for the remainder of the EVENT pulse. This active low output causes the output of a subsequent NAND gate 13 to be at a logic high level (irrespective of the logic state of the other input to gate 13) and counter circuit 14 triggers an alarm signal for a specified duration as a result. An oscillator 15 feeds reference signals to timer 10 and counter 14 which control the duration of the reference pulse and the duration of the alarm signal. The former is adjustable by a SET input to oscillator 15 and is typically 350 milliseconds.
In order to detect drastic disturbances of the security fence 1, the output of buffer amplifier 6 is fed to the inverting input of a differential amplifier 12, and compared with a reference voltage V REF at the non-inverting input. V REF is set at 6.8 volts by a zerer diode ZD which is connected via a resistor R37 to a supply rail V + . If the peak amplitude of the signals from envelope detector 5 exceed 6.8 volts, the output of differential amplifier 12 goes negative and feeds a logic low signal to one input of NAND gate 11 via a resistor R54, causing an alarm indication as a result. Thus NAND gate 13 acts as an OR gate.
In order to prevent the critical 3.55 ratio of input levels at comparator circuit 9 from being exceeded by very small signals when the threshold voltage generated by averaging circuit 7 is low, a low level D.C. voltage (approximately 100 mV) is applied to integrating capacitor C12 and capacitor C13 from the supply rail V + via a resistor R40 from a potential divider, consisting of resistors R41 and R39 across zener diode ZD. Thus the voltages across these capacitors (and hence the inputs to comparator circuit 9) tend to equalise under quiet conditions.
FIG. 3 shows the behaviour of the discriminator circuit arrangement of FIG. 2 in response to nine successive disturbances at the security fence 1.
It is assumed that there is initially little or no wind. Consequently the voltage V.sub.(C12) across capacitor C12 (which corresponds to the input to comparator circuit 9 from voltage divider 8) and the voltage V.sub.(C13) across capacitor C13 (which corresponds to the input to comparator circuit 9 from circuit 7) are both maintained at approximately 100 mV initially (FIG. 3(a)). Subsequently a sudden minor disturbance causes a sudden jump in V.sub.(C12), which gradually decays while V.sub.(C13) slowly rises to meet V.sub.(C12). No EVENT pulse is generated because the common 100 mV quiescent voltage prevents the 3.55 ratio (indicated by a dashed line in FIG. 3(b)) from being exceeded. Subsequently a larger disturbance (due e.g. to a sudden gust of wind) causes V.sub.(C12) to rise considerably. Consequently the ratio V.sub.(C12) :V.sub.(C13) briefly rises past 3.55 and a correspondingly brief EVENT Pulse is generated (FIG. 3(c)). The EVENT pulse persists for less than 350 ms and therefore no alarm signal is generated. V.sub.(C12) and V.sub.(C13) decay at the same rate through their common discharge path. A subsequent minor gust of wind causes a third peak in V.sub.(C12) but this occurs too long after the previous disturbance to affect the ratio V.sub.(C12) :V.sub.(C13) significantly. Therefore neither an EVENT pulse nor an alarm indication results. Next however two successive disturbances occur as a result of an attempt to climb the fence, and these sustain an EVENT pulse for sufficiently long to trigger an alarm signal, as shown in FIG. 3(c). Finally a wind build up causes a rapid succession of four peaks in V(C12) (corresponding to four successive gusts) and these cause four correspondingly short event pulses, which are however of insufficient duration to trigger an alarm signal. | An intruder alarm system of the type used to detect mechanical vibrations in a security fence or the like. Vibrations are assessed for alarm potential by detecting peak amplitudes against a dynamic vibration reference. A sufficient ratio between the two indicates an intrusion. | 6 |
RELATED APPLICATION
This application is a division of U.S. application Ser. No. 10/862,043 filed Jun. 3, 2004, now U.S. Pat. No. 7,391,372, which claims priority from U.S. Provisional application Ser. No. 60/483,318 filed Jun. 26, 2003.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
The present invention was made with support from the United States Government under Contract No. F33615-02-C-1241, awarded by the Department of the Air Force, Air Force Materiel Command, AFRL. The U.S. Government has certain rights in the invention.
TECHNICAL FIELD
The present invention relates to phased array antennas. More specifically, the present invention relates to an integrated phased array antenna with improved thermal properties and coupling efficiency.
BACKGROUND
Antenna systems are widely used in both ground based applications (e.g., cellular antennas) and airborne applications (e.g., airplane or satellite antennas). For example, so-called “smart” antenna systems, such as adaptive or phased array antennas, combine the outputs of multiple antenna elements with signal processing capabilities to transmit and/or receive communications signals (e.g., microwave signals, RF signals, etc.). As a result, such antenna systems can vary the transmission or reception pattern (i.e., “beam shaping” or “spoiling”) or direction (i.e., “beam steering”) of the communications signals in response to the signal environment to improve performance characteristics.
A typical phased array antenna may include, for example, one or more element controllers connected to a central controller. Among other functions, the element controllers process beam control commands generated by the central controller (e.g., beam steering signals and/or beam spoiling signals) and provide output control signals for each of the phased array antenna elements. More particularly, each antenna element may have a phase shifter, attenuator, delay generator, etc., and the output control signals from the element controller may be used to control a phase, attenuation, or delay thereof. Thus, the transmission or reception pattern may be varied, as noted above. In such phased array antennas, temperature changes may have a significant impact on phase shifters, attenuators, or operating frequencies of the phased array antenna that may result in undesirable signal characteristics. This problem is compounded by the fact that the power amplifiers driving these phased array antennas generate a relatively considerable amount of heat. Therefore, maintaining the operating temperature within a desirable range is critical to the performance of a phased array antenna system.
Phased array antennas are typically designed using either a “brick” architecture or a “tile” architecture. In a brick architecture, the active and passive communication components are mounted on rectangular Transmit Receive Modules (TRMs) that resemble bricks, and are placed behind the radiating elements perpendicular to the array face. In a tile architecture, the components are placed on small modules that mount parallel to the array face, much like common tiles. FIG. 1 depicts a schematic side view of a portion of a phased array system utilizing a tile architecture, including a transceiver device in the form of an integrated circuit (IC) chip 10 (such as a Monolithic Microwave IC or MMIC) mounted on an insulating substrate 20 . The insulating substrate is separated from an antenna substrate 30 by a ground plane 40 . Mounted upon the antenna substrate is an antenna element 50 for transmitting and receiving radio signals. The ground plane 40 is formed of an electrically conductive material and includes an opening 42 overlying the antenna element 50 . The insulating substrate 20 is typically formed of ceramic material, which is an excellent electrical insulator and also a poor heat conductor. Therefore, a cooling manifold 60 is usually located behind the chip 10 , on the side opposite the antenna elements 50 . This approach to cooling phased array antenna systems has been moderately successful, but entails the additional costs and complexity associated with the cooling manifold fabrication and attachment.
Components on tiles are typically mounting using standard “pick and place” and wirebonding techniques, which are costly and time consuming procedures that prohibit cost effective manufacturing of very large arrays. Coupling between the input/output antennas and the MMIC circuit is typically accomplished by transitioning off the communication chip using a standard technique (e.g. wire bonding), then transitioning to the antenna using other types of transitions. This technique has been known to adversely impact the efficiency of energy transfer between the communication chips and the antennas due to inaccurately placed or lossy wirebonds.
To avoid problems associated with the creation of plated-through holes (or vias), aperture coupling is a commonly used method for exciting patch antennas and has a number of advantages over other methods such as probe coupling or in-plane excitation from components mounted next to the antennas. Probe coupling through a ground plane aperture requires additional processing steps to provide conductive feed-through holes (vias) in the antenna substrate, which restricts the types of materials used for the antenna substrate (e.g., Sapphire is difficult to drill or etch through). On the other hand, mounting the MMIC components on the antenna substrate next to the antenna elements may eliminate the need for plated through holes, but this approach places the MMIC components directly within the radiated fields of the antenna array, potentially causing spurious coupling between different sections of the transmit or receive circuitry, and possibly causing spurious scattering of the radiated fields due to the additional circuitry present on the antenna layer. Additionally, this also reduces the surface area available for chip placement, which is already severely limited by the large areas typically occupied by the antenna elements. Aperture coupled patch antennas eliminate these issues by shielding the MMIC components safely behind a ground plane, and utilizing ground plane apertures to efficiently couple the signals to and from the antenna elements, without the need for plated through holes. As further shown in FIG. 1 , aperture coupling entails transitioning off the chip 10 using a wire bond 70 to a conductive microstrip 80 which couples electromagnetically with the antenna element 50 through the opening 42 in the ground plane 40 .
The present invention further improves upon the design of phased array antennas and enhances their operating efficiency by more efficient coupling and improved cooling performance.
SUMMARY
In a first embodiment as disclosed herein, a communication device comprises a substrate layer of substantially electrically nonconductive material having two substantially parallel surfaces, an antenna element disposed on one of the surfaces, a ground layer of substantially electrically conductive material disposed on the other surface and having an opening formed therethrough opposite from the antenna element, and a transceiver device mounted to the ground layer to transmit and/or receive electromagnetic energy through the opening.
In another embodiment disclosed herein, a phased array antenna device comprises a substrate layer of substantially electrically nonconductive material having two substantially parallel surfaces, a plurality of antenna elements disposed on one of the surfaces, a ground layer of substantially electrically conductive material disposed on the other surface and having an opening formed therethrough opposite from each antenna element, and a plurality of transceiver devices mounted to the ground layer to transmit and/or receive electromagnetic energy through the openings.
In a further embodiment disclosed herein, a communication device comprises a substrate layer of substantially electrically nonconductive material having two substantially parallel surfaces, an antenna element disposed on one of the surfaces, and a transceiver device disposed on the other surface to exchange electromagnetic energy with the antenna element.
In other embodiments, the transceiver device may be a monolithic microwave integrated circuit (MMIC). Additionally, the substrate layer may be formed of Aluminum Nitride or Sapphire. The antenna elements may be patch antennas.
These and other features and advantages will become further apparent from the detailed description and accompanying figures that follow. In the figures and description, numerals indicate various features, like numerals referring to like features throughout both the drawings and the description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic partial side view of a phased array antenna as known in the art;
FIG. 2 is a schematic partial side view of a communication system as disclosed herein;
FIG. 3 is a diagram of a phased array antenna device including an embodiment disclosed herein; and
FIG. 4 is a schematic view of another phased array antenna device including an embodiment disclosed herein.
DETAILED DESCRIPTION
With reference to FIG. 2 , in one embodiment a communication device such as a MMIC transceiver 10 is mounted directly to a surface of a ground plane 40 and overlying an opening 42 formed therein. The ground plane is formed of an electrically conductive material, is typically very thin, and is bonded on its other surface to an antenna substrate 30 that is formed of an electrically insulating material. Mounted upon the antenna substrate is an antenna element 50 for transmitting and receiving radio signals. The antenna substrate may be formed of a material such as sapphire or aluminum nitride.
In operation, the transceiver device 10 is electromagnetically coupled to the antenna element 50 through the opening 42 in the ground plane 40 . In this manner, the transceiver and the antenna element can exchange electromagnetic energy, such as when the antenna element receives radio signals that it radiates to the transceiver through the opening 42 , or when the transceiver transmits electromagnetic signals through the opening to be picked up by the antenna element and transmitted as radio signals. During operation, the transceiver device emits heat generated by its internal components. Because the antenna substrate 30 is composed of a material such as sapphire or aluminum nitride, which have good heat transfer properties, the heat generated by the transceiver device is transmitted through the thin, metallic ground plane 40 and into the substrate, from where it is quickly and efficiently dissipated into the environment.
In accordance with the embodiments described above, an improved communication device such as a phased array antenna may be manufactured to exhibit improved efficiency and cooling. For instance, as shown in FIG. 3 , the embodiments disclosed herein may be used to create advanced phased array systems. The antenna array forms the foundation upon which the front-end RF components and signal processing electronics are registered and assembled. An aperture coupled antenna fed in accordance with the principles disclosed herein enables the input and output antenna elements 50 to be fully integrated with the front-end MMIC components in a way that achieves high RF efficiency and excellent thermal management of the MMIC components while retaining the advantages of the large scale self-assembly. This approach achieves these goals by electromagnetically coupling the MMIC component directly to a patch antenna radiator 55 through an aperture in the MMIC ground as illustrated by the double arrow 100 in FIG. 3 .
In an embodiment, a template transfer method may be used to enable mass integration of precisely registered arrays of high performance front-end RF components with such an antenna array. In this approach, high performance components including InP MMICs based on high electron-mobility transistors (HEMTs, suitable for Low Noise Amplifiers) and heterojunction bipolar transistors (HBTs, suitable for high power amplifiers and sources) may be directly bonded to the antenna assembly and thereby enable proper thermal management. Planarization layers may be applied to the MMIC components comprising RF compatible materials and patterned metal transmission lines and transitions may be fabricated to provide interconnection within and between components. Baseband signals can be converted to and from microwave frequencies by Schottky diode mixers that receive a pump signal being coherently distributed to the array from neighboring InP HBT-based oscillators. CMOS circuits shielded from the RF circuitry may be used to provide control, data conversion, and digital signal processing. Silicon CMOS is a technology well suited to processing the complex baseband waveforms used by spectrally efficient communications systems and radars, as well as data storage, analysis, and network and programming interfaces.
The novel embodiments described herein may also be utilized to achieve integration of multiple device technologies. To accomplish this, the input and output antennas must also be fully integrated with the MMIC components in a way that achieves high RF efficiency while retaining the advantages of large scale fluidic self assembly. The embodiments disclosed herein achieve these goals by electromagnetically coupling the MMIC component 10 directly to a patch antenna radiator 50 through an aperture 42 in the MMIC ground plane 40 , as previously described and also as further shown in FIG. 4 . Aperture coupling between the antennas 50 and MMICs 10 allows for the utilization of antenna substrate materials that offer certain advantages, but would produce fabrication difficulties for probe fed antennas. Sapphire or Aluminum Nitride (AlN) provide a good thermal path for heat generated within the MMIC components, while ensuring low millimeter wave (mmW) losses. The MMIC components may be bonded directly to the antenna substrate to transfer mmW energy between the antenna and the MMIC through an aperture in both the antenna ground plane and MMIC backside ground. A microstrip line located on the MMIC chip may excite the aperture and connect directly to active MMIC circuitry.
Aperture coupling of antennas provides a simple and efficient method of excitation, but extraneous radiation may occur within the buried circuit layers. The MMIC components are located between two ground planes, one functioning as the RF ground plane 40 for the antenna and RF/mmW elements, and the other for the Silicon signal processing. Because apertures are bi-directional radiators, it is possible for a significant amount of power to be radiated into the areas between the ground planes, thus reducing overall efficiency and possibly introducing unwanted spurious coupling effects. To eliminate this spurious coupling, the two ground planes may be shorted together using an array of plated-through holes located less than one half of a wavelength in the material (˜400 microns). It is important to note that the plated-through holes are not required in the antenna substrate 30 , which also serves as the heat conduction path. The materials chosen for the MMIC spacer layer must accommodate plated-through holes. An example of a suitable material is high resistivity silicon.
Typical circuitry on a W band MMIC chip consists of Coplanar Waveguides (CPW) connecting InP HEMT devices, with integrated vias 110 that connect the top and bottom side grounds on opposite sides of the chip. The proximity of the additional signal processing circuit ground to the RF circuitry can adversely impact RF performance if that ground is located too close to the MMIC components. The appropriate spacing depends on the type of material used for the MMIC spacer layer, and can be determined by EM simulation. In one embodiment it is anticipated that the spacer layer will be thicker than the expected thickness of the MMIC component (˜50 microns).
In another embodiment, RF interconnects may be fabricated in accordance with the principles disclosed herein. High-performance interconnections are essential for horizontal transport of DC and RF signals among MMIC front-end components and for vertical connection to Si signal processing electronics. The novel embodiments disclosed herein precisely orient components with respect to one another and the antenna array. This enables, through the use of standard RF circuit processing techniques, the creation of a wide variety of transmission lines maintaining excellent performance. Such structures include conductors with one or two ground planes (microstrip and stripline, respectively), coplanar strips (CPS) and three-conductor coplanar waveguides (CPW) as shown in FIG. 4 . These transmission lines are used extensively in MMICs and conventional RF printed circuits. Using low-loss dielectrics and mode suppression techniques developed for millimeter-wave MMICs and subsystems, operation at frequencies up to ˜100 GHz may be practical. The capacity for fabricating RF interconnects between dissimilar ICs with controlled impedance, coupling, and radiation characteristics is one of the unique potential benefits of the embodiments disclosed herein.
Having now described the invention in accordance with the requirements of the patent statutes, those skilled in this art will understand how to make changes and modifications to the present invention to meet their specific requirements or conditions. Such changes and modifications may be made without departing from the scope and spirit of the invention as disclosed herein. | An integrated communication device having a substrate layer of substantially electrically nonconductive material with two substantially parallel surfaces, an antenna element disposed on one of the surfaces, a ground layer of substantially electrically conductive material disposed on the other surface and having an opening formed therethrough opposite from the antenna element, and a transceiver device mounted to the ground layer to transmit and/or receive electromagnetic energy through the opening. | 7 |
TRADEMARKS
IBM® is a registered trademark of International Business Machines Corporation, Armonk, N.Y., U.S.A. Other names used herein may be registered trademarks, trademarks or product names of International Business Machines Corporation or other companies.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to file system presentations, and particularly to systems, methods, and computer program products for graphical user interface presentation to implement filtering of a large unbounded hierarchy to avoid repetitive navigation.
2. Description of Background
In file system presentations there are mechanisms that allow the user to create shortcuts using the functionality of the system e.g. links, or create shortcuts in the presentation layer to go directly to one of the branches of the hierarchy. In database systems filtering is typically accomplished by writing some SQL, or interacting with some dialog interface to filter the data returned, which in turn modifies a query. For example, a user must interact with a dialog. navigate and reproduce the view they already have in their tree display to create a filter, which is exactly the problem that creating a filter should address.
When navigating large databases of hierarchical information, users must often traverse though multiple levels of the hierarchy to navigate to the location in the hierarchy in which they have an interest. Systems that do not persist the expansion of the hierarchy from one session to the next require that the user perform this navigation in any new session where they want to navigate to the same location. Systems that do persist the expansion do so at the expense of recreating the expansion automatically and filling the user interface with the hierarchy above the location of interest. In either approach, the representation of the hierarchy is complete from the root of the hierarchy down to the location of interest, often forcing the user to see a large amount of extraneous information.
There are many kinds of filtering mechanisms available in products available in the marketplace. For example, type based filters allow the user to pick from a list of object types they either want to include or exclude in the hierarchical display. Some filtering mechanisms allow the user to specify a logical expression that includes one or more properties of an object, and include or exclude objects where the expressions match. The Eclipse framework includes a mechanism called “Working Sets” that allows the user to arbitrarily choose nodes in the hierarchy to include in a named working set, and then specify which working set is visible in the hierarchy at any given time. In the Eclipse approach, the user must find the objects of interest in a popup dialog rather than immediately in the view they are operating in, and the resulting filtered view includes all objects between the selected objects and the root.
SUMMARY OF THE INVENTION
Exemplary embodiments include a method of graphical user interface presentation to implement filtering of the file hierarchy tree, the method including retrieving the file hierarchy tree for presentation on the display, the file hierarchy tree representative of a plurality of nodes, navigating the file hierarchy tree to identify nodes for selection in a sub-group of nodes, for each of the sub-group of nodes of the plurality of nodes, receiving a node selection signal indicative of the selection device pointing on a selected node from the file hierarchy tree, in response to the node selection signal, presenting the selected node with a highlight on the display, receiving a menu selection signal indicative of the selection device pointing at one of the sub-group of nodes, in response to the menu selection signal, displaying a menu on the display including an option to create a filter, receiving a filter creation selection signal indicative of the selection device pointing at the option to create the filter, in response to receiving the filter creation signal, displaying a popup dialog box on the display, the popup dialog box including an option to create a new filter and edit an existing filter, receiving a dialog box selection signal indicative of the selection device pointing at a selection button on the dialog box and displaying a filtered hierarchy tree on the display, the filtered hierarchy tree including the sub-group of nodes. The method can further include in response to the dialog box selection signal, receiving a new filter name when a create a new filter selection signal is received with the dialog box selection signal. The method can further include in response to the dialog box selection signal, receiving an existing filter name, and a modified sub-group of nodes when an edit an existing filter selection signal is received with the dialog box selection signal.
System and computer program products corresponding to the above-summarized methods are also described and claimed herein.
Additional features and advantages are realized through the techniques of the present invention. Other embodiments and aspects of the invention are described in detail herein and are considered a part of the claimed invention. For a better understanding of the invention with advantages and features, refer to the description and to the drawings.
TECHNICAL EFFECTS
As a result of the summarized invention, technically we have achieved a solution, which provides systems and methods that enable the user to select as many nodes in the hierarchy as they want, and then gesture to create a filtered view that shows only those nodes they selected at the root of the tree. In creating the filter, the user names the filter so that they may reuse it in the future. The user may switch between filters, and between filtered and unfiltered views of the data.
BRIEF DESCRIPTION OF THE DRAWINGS
The subject matter which is regarded as the invention is particularly pointed out and distinctly claimed in the claims at the conclusion of the specification. The foregoing and other objects, features, and advantages of the invention are apparent from the following detailed description taken in conjunction with the accompanying drawings in which:
FIG. 1 illustrates an exemplary embodiment of a system for graphical user interface presentation to implement filtering of a large unbounded hierarchy to avoid repetitive navigation;
FIG. 2 illustrates an exemplary file hierarchy tree;
FIG. 3 illustrates the file hierarchy tree of FIG. 2 in which the user has selected a “Filter . . . ” command in accordance with exemplary embodiments;
FIG. 4 illustrates an exemplary popup dialog in accordance with exemplary embodiments;
FIG. 5 illustrates a filtered hierarchy tree in accordance with exemplary embodiments; and
FIG. 6 illustrates a flowchart of a method for graphical user interface presentation to implement filtering of a large unbounded hierarchy to avoid repetitive navigation in accordance with exemplary embodiments.
The detailed description explains the preferred embodiments of the invention, together with advantages and features, by way of example with reference to the drawings.
DETAILED DESCRIPTION OF THE INVENTION
In exemplary embodiments, the systems and methods described herein, the user can specify a filter by using the representation of the hierarchy that the user has been navigating, and can present the filtered objects as new root objects such that the user is not exposed to extraneous hierarchical objects between the objects of interest and the root object. In exemplary embodiments, specifying a filter is faster and requires many fewer mouse clicks, and the resulting filtered view is void of extraneous nodes, thereby simplifying interaction.
FIG. 1 illustrates an exemplary embodiment of a system 100 for graphical user interface presentation to implement filtering of a large unbounded hierarchy to avoid repetitive navigation. The methods described herein can be implemented in software (e.g., firmware), hardware, or a combination thereof. In exemplary embodiments, the methods described herein are implemented in software, as an executable program, and is executed by a special or general-purpose digital computer, such as a personal computer, workstation, minicomputer, or mainframe computer. The system 100 therefore includes general-purpose computer 101 .
In exemplary embodiments, in terms of hardware architecture, as shown in FIG. 1 , the computer 101 includes a processor 101 , memory 110 coupled to a memory controller 115 , and one or more input and/or output (I/O) devices 140 , 145 (or peripherals) that are communicatively coupled via a local input/output controller 135 . The input/output controller 135 can be, for example but not limited to, one or more buses or other wired or wireless connections, as is known in the art. The input/output controller 135 may have additional elements, which are omitted for simplicity, such as controllers, buffers (caches), drivers, repeaters, and receivers, to enable communications. Further, the local interface may include address, control, and/or data connections to enable appropriate communications among the aforementioned components.
The processor 105 is a hardware device for executing software, particularly that stored in memory 110 . The processor 105 can be any custom made or commercially available processor, a central processing unit (CPU), an auxiliary processor among several processors associated with the computer 101 , a semiconductor based microprocessor (in the form of a microchip or chip set), a macroprocessor, or generally any device for executing software instructions.
The memory 110 can include any one or combination of volatile memory elements (e.g., random access memory (RAM, such as DRAM, SRAM, SDRAM, etc.)) and nonvolatile memory elements (e.g., ROM, erasable programmable read only memory (EPROM), electronically erasable programmable read only memory (EEPROM), programmable read only memory (PROM), tape, compact disc read only memory (CD-ROM), disk, diskette, cartridge, cassette or the like, etc.). Moreover, the memory 110 may incorporate electronic, magnetic, optical, and/or other types of storage media. Note that the memory 110 can have a distributed architecture, where various components are situated remote from one another, but can be accessed by the processor 105 .
The software in memory 110 may include one or more separate programs, each of which comprises an ordered listing of executable instructions for implementing logical functions. In the example of FIG. 1 , the software in the memory 110 includes the graphical user interface presentation methods described herein in accordance with exemplary embodiments and a suitable operating system (OS) 111 . The operating system 111 essentially controls the execution of other computer programs, such the graphical user interface presentation systems and methods described herein, and provides scheduling, input-output control, file and data management, memory management, and communication control and related services.
The graphical user interface presentation methods described herein may be in the form of a source program, executable program (object code), script, or any other entity comprising a set of instructions to be performed. When a source program, then the program needs to be translated via a compiler, assembler, interpreter, or the like, which may or may not be included within the memory 110 , so as to operate properly in connection with the OS 111 . Furthermore, the graphical user interface presentation methods can be written as an object oriented programming language, which has classes of data and methods, or a procedure programming language, which has routines, subroutines, and/or functions.
In exemplary embodiments, a conventional keyboard 150 and mouse 155 can be coupled to the input/output controller 135 . Other output devices such as the I/O devices 140 , 145 may include input devices, for example but not limited to a printer, a scanner, microphone, and the like. Finally, the I/O devices 140 , 145 may further include devices that communicate both inputs and outputs, for instance but not limited to, a NIC or modulator/demodulator (for accessing other files, devices, systems, or a network), a radio frequency (RF) or other transceiver, a telephonic interface, a bridge, a router, and the like. The system 100 can further include a display controller 125 coupled to a display 130 . In exemplary embodiments, the system 100 can further include a network interface 160 for coupling to a network 165 . The network 165 can be an IP-based network for communication between the computer 110 and any external server, client and the like via a broadband connection. The network 165 transmits and receives data between the computer 101 and external systems. In exemplary embodiments, network 165 can be a managed IP network administered by a service provider. The network 165 may be implemented in a wireless fashion, e.g., using wireless protocols and technologies, such as WiFi, WiMax, etc. The network 165 can also be a packet-switched network such as a local area network, wide area network, metropolitan area network, Internet network, or other similar type of network environment. The network 165 may be a fixed wireless network, a wireless local area network (LAN), a wireless wide area network (WAN) a personal area network (PAN), a virtual private network (VPN), intranet or other suitable network system and includes equipment for receiving and transmitting signals.
If the computer 101 is a PC, workstation, intelligent device or the like, the software in the memory 110 may further include a basic input output system (BIOS) (omitted for simplicity). The BIOS is a set of essential software routines that initialize and test hardware at startup, start the OS 111 , and support the transfer of data among the hardware devices. The BIOS is stored in ROM so that the BIOS can be executed when the computer 101 is activated.
When the computer 101 is in operation, the processor 105 is configured to execute software stored within the memory 110 , to communicate data to and from the memory 110 , and to generally control operations of the computer 101 pursuant to the software. The graphical user interface presentation methods described herein and the OS 111 , in whole or in part, but typically the latter, are read by the processor 105 , perhaps buffered within the processor 105 , and then executed.
When the systems and methods described herein are implemented in software, as is shown in FIG. 1 , it the methods can be stored on any computer readable medium, such as storage 120 , for use by or in connection with any computer related system or method. In the context of this document, a computer readable medium is an electronic, magnetic, optical, or other physical device or means that can contain or store a computer program for use by or in connection with a computer related system or method. The graphical user interface presentation methods described herein can be embodied in any computer-readable medium for use by or in connection with an instruction execution system, apparatus, or device, such as a computer-based system, processor-containing system, or other system that can fetch the instructions from the instruction execution system, apparatus, or device and execute the instructions. In exemplary embodiments, a “computer-readable medium” can be any means that can store, communicate, propagate, or transport the program for use by or in connection with the instruction execution system, apparatus, or device. The computer readable medium can be, for example but not limited to, an electronic, magnetic, optical, electromagnetic, infrared, or semiconductor system, apparatus, device, or propagation medium. More specific examples (a non-exhaustive list) of the computer-readable medium would include the following: an electrical connection (electronic) having one or more wires, a portable computer diskette (magnetic), a random access memory (RAM) (electronic), a read-only memory (ROM) (electronic), an erasable programmable read-only memory (EPROM, EEPROM, or Flash memory) (electronic), an optical fiber (optical), and a portable compact disc read-only memory (CDROM) (optical). Note that the computer-readable medium could even be paper or another suitable medium upon which the program is printed, as the program can be electronically captured, via for instance optical scanning of the paper or other medium, then compiled, interpreted or otherwise processed in a suitable manner if necessary, and then stored in a computer memory.
In exemplary embodiments, where the graphical user interface presentation methods are implemented in hardware, the graphical user interface presentation methods described herein can implemented with any or a combination of the following technologies, which are each well known in the art: a discrete logic circuit(s) having logic gates for implementing logic functions upon data signals, an application specific integrated circuit (ASIC) having appropriate combinational logic gates, a programmable gate array(s) (PGA), a field programmable gate array (FPGA), etc.
In exemplary embodiments, one or more processes in the memory 110 can monitor activity from the keyboard 150 and the mouse 155 or a combination thereof. The processes can further monitor long-running jobs that have been initiated on the computer 101 . The processes can further monitor which and how many other machines can control the computer 101 either locally or remotely. In exemplary embodiments, the processes can also inquire or accept a grace period input by a user of the computer 101 . The grace period can be a time period after which all traffic to and from the computer ceases if no further activity has been sensed by the processes. In this way, if a user has left the computer 101 for an extended period of time or has left the computer (e.g., after a work day) the computer 101 no longer allows traffic to and from the computer 101 . In an alternative implementation, the computer 101 can totally power down after the grace period has expired. In further exemplary embodiments, the processes can accept traffic only from a common network maintenance control system that provides limited services.
In exemplary embodiments, the user can interact directly with the presentation they are using to create the filter. In exemplary embodiments, the user has already navigated through the hierarchy and does not want to repeat the navigation. The systems and methods described herein enable the user to select as many nodes in the hierarchy as they want, and then gesture to create a filtered view that shows only those nodes they selected at the root of the tree. In creating the filter, the user names the filter so that they may reuse it in the future. The user may switch between filters, and between filtered and unfiltered views of the data.
FIG. 2 illustrates a file hierarchy tree 200 in which the user has selected any nodes in the tree 200 that the user would like to see in a filtered view in accordance with exemplary embodiments. In this example five nodes are selected. FIG. 3 illustrates the file hierarchy tree 200 of FIG. 2 in which the user has selected a “Filter . . . ” command from a menu 300 in accordance with exemplary embodiments. FIG. 4 illustrates an exemplary popup dialog 400 . In the popup dialog 400 , the user can type in a name for the filter and hit “OK”. FIG. 5 illustrates a filtered hierarchy tree 500 in accordance with exemplary embodiments. The tree 500 now shows only the nodes selected for the filter as root nodes. If necessary, context may be shown for the selection in an address bar or a hover bubble.
In exemplary embodiments, the user may select directly in their tree view to create the filter by pointing and clicking. Furthermore, the filter is named, persistent and reusable. In addition, the filter may be constructed using any nodes visible to the user in the tree.
FIG. 6 illustrates a flowchart of a method 600 for graphical user interface presentation to implement filtering of a large unbounded hierarchy to avoid repetitive navigation in accordance with exemplary embodiments. At block 610 , the method 600 retrieves the file hierarchy tree having a series of nodes for presentation on the display 130 . At block 620 , the user can navigate the file hierarchy tree to identify nodes for selection in a sub-group of nodes. At block 630 , the user selects the nodes for a filtered view. In exemplary embodiments, for each of the sub-group of nodes, the method 600 highlights each of the selected nodes on the display 130 as shown in FIG. 2 . The user can then select a Filter command as shown in FIG. 3 at block 640 . At block 650 , the user can select a filter name, either by creating a new filter or editing an existing filter, in which case, the user can add or remove nodes for the filtered view. At block 660 , the method 600 then displays the filtered hierarchy tree as shown in FIG. 5 .
The exemplary embodiments of the graphical user interface presentation systems and methods described herein have been described with respect to file system presentations. It is appreciated that in other exemplary embodiments, the systems and methods described herein can present any hierarchal data represented in a tree.
The capabilities of the present invention can be implemented in software, firmware, hardware or some combination thereof.
As one example, one or more aspects of the present invention can be included in an article of manufacture (e.g., one or more computer program products) having, for instance, computer usable media. The media has embodied therein, for instance, computer readable program code means for providing and facilitating the capabilities of the present invention. The article of manufacture can be included as a part of a computer system or sold separately.
Additionally, at least one program storage device readable by a machine, tangibly embodying at least one program of instructions executable by the machine to perform the capabilities of the present invention can be provided.
The flow diagrams depicted herein are just examples. There may be many variations to these diagrams or the steps (or operations) described therein without departing from the spirit of the invention. For instance, the steps may be performed in a differing order, or steps may be added, deleted or modified. All of these variations are considered a part of the claimed invention.
While the preferred embodiment to the invention has been described, it will be understood that those skilled in the art, both now and in the future, may make various improvements and enhancements which fall within the scope of the claims which follow These claims should be construed to maintain the proper protection for the invention first described. | Systems, methods, and computer program products for graphical user interface presentation to implement filtering of a large unbounded hierarchy. Exemplary embodiments include a method including retrieving the file hierarchy tree for presentation on the display, the file hierarchy tree representative of a plurality of nodes, navigating the file hierarchy tree to identify nodes for selection in a sub-group of nodes, receiving a node selection signal, presenting the selected node with a highlight on the display, receiving a menu selection signal, displaying a menu on the display including an option to create a filter, receiving a filter creation selection signal, displaying a popup dialog box on the display, the popup dialog box including an option to create a new filter and edit an existing filter, receiving a dialog box selection signal and displaying a filtered hierarchy tree on the display, the filtered hierarchy tree including the sub-group of nodes. | 6 |
This is a continuation-in-part patent application claiming priority to U.S. patent application Ser. No. 11/928,541, filed Oct. 30, 2007, which claims priority to U.S. patent application Ser. No. 11/084,291, filed Mar. 19, 2005, which claims priority to U.S. patent application Ser. No. 10/939,246, filed Sep. 10, 2004, which claims priority to application Ser. Nos. 10/623,222 filed Jul. 21, 2003 (U.S. Pat. No. 6,935,074, issued Aug. 30, 2005) and 10/693,473, filed Oct. 24, 2003 (U.S. Pat. No. 7,082,723, issued Aug. 1, 2006).
BACKGROUND OF THE INVENTION
1. Field of the Invention
Applicant's invention relates to a gutter retaining system for affixing a gutter to a building without placing holes in the gutter. More specifically, the present invention relates to an interlocking system that incorporates a gutter clip and a gutter hanger to affix the gutter to a retaining clip attached to a fascia board of a building, thereby eliminating the need to place holes in the gutter itself to insert screws or nails. The gutter hanger of the gutter retaining system is constructed of a single piece and incorporates an upper portion designed to support a leaf protection device. Alternatively, the upper portion is removably attached to the gutter hanger.
2. Description of the Related Art
For years property owners have struggled with the destructive effects of water on their buildings. However, by channeling the water away from the structure, building owners can reduce the damage caused by water. This can be accomplished through the use of a gutter system to channel water off the roof and away from the foundation. However, any damaged lengths of gutter or drain pipe caused by wear, improper installation, or sagging can cause leaks which can result in water damage to the building.
Traditionally, gutters have been attached by nailing the gutter directly to the building. Building contractors typically used a spike and ferrule system, in which a narrow, tubular spacer, the ferrule, is placed between the front wall of a gutter and its rear wall, ensuring that the front wall remains at a uniform distance from the rear wall. A spike or long nail is then punched through the outside of the front wall of the gutter, through the ferrule, through the back wall of the gutter, and into the wall or fascia board of the building.
A gutter installed in this way ends up with its front wall tilted forward towards the ground. Once this occurs the captured rainwater and other debris tends to pool along the outer edge of the gutter causing the weight on the outer edge of the gutter to increase, thus resulting in the gutter pulling away from the wall or fascia board. Further, while this manner of installation temporarily secures the gutter in place, it does not ensure that water will not run behind the gutter. If water is allowed to run and collect behind the gutter, eventually the integrity of the wood or fascia board begins to weaken and the gutter is slowly pulled away from the building.
The utilization of gutter hangers is the most common way in which installers have tried to improve the integrity and life of gutter systems. A gutter hanger is basically a modified spacer that is shaped like a flat plate, with both ends mined upward. A first end of the gutter hanger is inserted under the lip of the front wall of the gutter, typically located along the inner surface of the front wall of the gutter, along the top thereof. The second end, with a pre-punched nail hole, is placed against the rear wall of the gutter. A nail or screw is then inserted through the nail hole, through the rear wall of the gutter, and into the building wall or fascia board. A variation of this method includes placing the second end of the gutter hanger over the top of the rear wall of the gutter. The gutter hanger is then nailed directly into the building wall or fascia board. While these methods of installation eliminate the need for inserting the nail or screw through the front wall of the gutter, a hole is still placed through the back wall of the gutter.
Another problem associated with gutter systems is the collection of leaves, dirt and other debris in addition to water. Collection of such extraneous matter adds substantial weight to the gutter, often resulting in bending or deforming the gutter, or the gutter tearing away from the building or fascia board. As a way to prevent leaves, dirt and other debris from entering the gutter, many different leaf protection devices have emerged. Leaf protection devices are typically installed over the gutter in a manner as to substantially cover the gutter while leaving small areas of the gutter exposed so that water may collect therein. Yet, installation of such leaf protection devices—especially on preexisting gutters—is often cumbersome and time consuming.
The reason that installation of leaf protection devices is cumbersome and time consuming is that in order to install most leaf protection devices, brackets must also be installed to support those devices. Typically, the brackets need to be installed onto the gutter hangers. Yet, only certain brackets are appropriate to be installed on certain hangers. Therefore, often times not only do brackets need to be installed, but gutter hangers must be replaced as well. As a result, the nails or screws must be removed from the gutter hangers. Thus, the entire gutter system must be taken down, the gutter hangers must be changed out, the brackets must be installed, and then the gutter system must be reinstalled on the same building. Only then is it possible to install the leaf protection device.
It is therefore desirable to provide a gutter system that affixes a gutter to a building without placing holes in the gutter. It is also desirable to provide a system for affixing a gutter which reinforces the integrity of the gutter to prevent the gutter from sagging or tearing away from the building. It is also desirable to provide a gutter hanger which is constructed to incorporate support brackets to support a leaf protection device. Alternatively, it is desirable to provide a gutter hanger that is designed to allow the optional addition of support brackets at a later time with ease, and without needing to replace the gutter hanger.
BRIEF SUMMARY OF THE INVENTION
The gutter system of the present invention provides the advantage of affixing a gutter to a building or fascia board of a building without placing holes in the gutter. The gutter system of the present invention also provides the advantages of providing reinforcement of the structural integrity of the gutter while providing support brackets to support a leaf protection device. The gutter system of the present invention incorporates a gutter clip and a gutter hanger to affix the gutter to a retaining member. The retaining member has a flat vertical portion which rests flush against a fascia board of a building in the preferred embodiment. The retaining member is attached to the fascia board by a nail or screw, and is the only site of attachment of the present system to the fascia board itself. The retaining member extends vertically along the vertical portion above the screw or nail. An arm portion of the retaining member extends downwardly and outwardly from a top portion of the retaining member, and terminates in a hook portion which angles inward and upward toward the vertical portion. Thus, a hook is formed by the retaining member to hold the gutter hanger therein.
A gutter clip is designed to attach directly to the gutter. The gutter clip has a vertical portion which is disposed against the outer surface of the rear wall of the gutter, between the gutter and the fascia board. Along the lower end of the vertical portion of the gutter clip, a horizontal spacer extends outward toward the fascia board, and terminates in a vertical protrusion which extends upward and is substantially parallel to the vertical portion. This spacer portion of the gutter clip facilitates keeping the gutter substantially level where there are substantial spaces or overlay between the fascia board and the overhang of shingles, or where the fascia board is tilted inward, toward the building or structure. A hanging portion of the gutter clip is located along the top portion of the gutter clip. The hanging portion curves downward on the side of the vertical portion opposite the spacer portion, creating a cavity for receiving a top edge of the rear wall of the gutter. The hanging portion curves slightly past parallel with the vertical portion, such that it is angled slightly toward the vertical portion. Thereafter, the hanging portion terminates in an end portion which angles slightly downward and away from the vertical portion of the gutter clip.
A gutter hanger of the preferred embodiment has a hanger portion which has a first end. The first end has a vertical wall extending substantially vertically and an inward wall which projects inward, toward a vertical portion of the gutter hanger, and slightly upward. The second end is opposite the first end, and has a vertical wall extending upward from the hanger portion, and a hanging portion which curves outward toward the fascia board and then downward along the vertical portion of the retaining member, as described herein below. The intermediate section of the gutter hanger is disposed between the first and second ends and generally spans the width of the gutter, thereby maintaining the shape and structural integrity of the gutter.
A vertical portion of the gutter hanger extends vertically from the intermediate section and terminates in a top portion of the gutter hanger. The vertical portion and the top portion form the bracket support to support a leaf protection device. The top portion has a front section which generally conforms to the shape of a front portion of the leaf protection device. The rear section of the top portion extends toward the roof of the building, terminating above the intermediate section of the hanger portion. At the end of the rear section, there is a knob or boss which is substantially “C” shaped.
The gutter clip slides over the top edge of the back wall of a gutter such that the vertical portion of the gutter clip is substantially flush with the outer surface of the back wall of the gutter, with the horizontal spacer aligning outward. The top of the back wall of the gutter slides into the hanging portion, such that part of the hanging portion and the end portion are on the inner surface of the back wall of the gutter.
The gutter hanger is then inserted into the gutter. The inward wall of the first end of the gutter hanger engages the lip on the inner surface of the front wall of the gutter, and the vertical wall of the first end of the gutter hanger abuts against a portion of the front wall of the gutter. The second end of the gutter hanger is placed over the gutter clip such that the vertical wall of the second end of the gutter hanger contacts the hanging portion and the end portion of the gutter clip on the inside of the rear or back wall of the gutter. The hanging portion of the gutter hanger then wraps around the hanging portion of the gutter clip. The intermediate section of the gutter hanger is disposed within the gutter and lies across the width of the gutter.
The gutter, gutter clip, and gutter hanger are installed on the building by placing the gutter hanger between the vertical portion and the hook portion of the retaining member. After securing the gutter, a leaf protection device may be installed over the top portion of the gutter hanger. Screws or nails can be placed through the leaf protection device and into the top portion of the gutter hanger to secure the leaf protection device to the hanger.
Optionally, prior to installing the leaf protection device, a support strap may be removably attached to the top portion. The support strap has a clip for receiving the knob on the rear section of the top portion of the gutter clip. The clip snaps onto the knob, and the strap extends toward the roof, where it can be attached to the roof using nails or screws. As installed, the support strap relieves part of the stress placed on the top portion and the vertical portion of the gutter clip by the leaf protection device.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the gutter system of the present invention with a leaf protection device;
FIG. 2 is a side view of the gutter system of the present invention showing the leaf protection device resting on the gutter hanger;
FIG. 3 is a perspective view of the gutter hanger of the present invention;
FIG. 4 is a perspective view of an alternative embodiment of the gutter hanger of the present invention;
FIG. 5 is a side view of an alternative embodiment of the gutter hanger of the present invention;
FIG. 6 is a perspective view of the gutter system of the present invention with the alternative embodiment of the gutter hanger;
FIG. 7 is a side view of the gutter system of the present invention showing the leaf protection device resting on the alternative embodiment of the gutter hanger;
FIG. 8 is a perspective view of the retaining member of the present invention;
FIG. 9 is a perspective view of the gutter clip of the present invention;
FIG. 10 is a perspective view of the support strap of the present invention.
FIG. 11 is a side view of an alternative embodiment of the gutter hanger of the present invention; and
FIG. 12 is a side view of the gutter system of the present invention with an alternative embodiment of the gutter hanger.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIGS. 1 , 2 and 3 , the gutter system 10 of the present invention is disclosed. The gutter system 10 comprises a gutter hanger 12 , a gutter clip 14 and a retaining member 16 . As shown in FIGS. 2 and 8 , the retaining member has a vertical portion 16 a which lies flush against a fascia board 18 , and is secured thereto by a screw 20 . In the present gutter system 10 , the screw 20 being place through the retaining member 16 and into the fascia board 18 is the only point of attachment between the gutter 22 and the building or structure (not shown). However, a nail or other appropriate attaching device could be used in place of the screw 20 . The retaining member 16 has an arm 16 b on the upper end of vertical portion 16 a which extends downward and outward from the upper end of the vertical portion 16 a . A hook portion 16 c is contiguous with arm 16 b , and angles inward and upward toward vertical portion 16 a . As discussed in detail below, the gutter clip 14 and gutter hanger 12 are secured to the retaining member 16 between the hook portion 16 c and the vertical portion 16 a.
Furthermore, although the retaining member 16 is shown and described as having a vertical member that is flush against the fascia board 18 , various modifications of the retaining member 16 could be made. For instance, the modifications disclosed in U.S. patent application Ser. No. 10/939,246, wherein a horizontal spacer extends from a lower part of vertical portion 16 a opposite arm 16 b and hook portion 16 c to accommodate different slanting angles of the fascia board 18 .
Referring to FIGS. 2 and 9 , the gutter clip 14 of the gutter system 10 is shown. The gutter clip 14 has a vertical portion 14 a . At a lower end of vertical portion 14 a , a horizontal spacer 14 b extends outward, and a vertical protrusion 14 c extends upward, substantially parallel to vertical portion 14 a from the end of the spacer 14 b . The spacer 14 b aides in keeping the gutter substantially level when the gutter hanger 12 is attached to the retaining member 16 . Thus, spacer 14 b separates the rear wall 22 a of the gutter 22 from the fascia board 18 . A hanging portion 14 d of the gutter clip 14 is located along the top of the gutter clip 14 . The hanging portion 14 d curves downward on the side of vertical portion 14 a opposite spacer 14 b , creating a cavity for receiving a top portion of the rear wall 22 a of gutter 22 . Hanging portion 14 d curves past parallel with vertical portion 14 a to angle slightly toward vertical portion 14 a . Thereafter, hanging portion 14 d terminates in an end portion 14 e which angles downward and outward from said vertical portion 14 a.
Hanging portion 14 d of gutter clip 14 slides over the top edge of rear wall 22 a of gutter 22 . As engaged with rear wall 22 a , vertical portion 14 a of gutter clip 14 is substantially flush with the outer surface of rear wall 22 a , and spacer 14 b is aligned outward from rear wall 22 a . The top of rear wall 22 a slides into the cavity between vertical portion 14 a and hanging portion 14 d such that part of hanging portion 14 d and end portion 14 e are disposed along the inner surface of rear wall 22 a . Hanging portion 14 d and end portion 14 e are then crimped toward vertical portion 14 a using a pair of pliers or other suitable crimping device, thus securing gutter 22 to gutter clip 14 .
Referring to FIGS. 1 , 2 and 3 , the preferred embodiment of gutter hanger 12 is disclosed. In the preferred embodiment, gutter hanger 12 is constructed of a single piece, having a hanger portion 26 , a vertical portion 28 and a top portion 30 . Hanger portion 26 reinforces and helps maintain the structural shape and integrity of gutter 22 , whereas vertical portion 28 and top portion 30 serve as a support bracket for a leaf protection device 24 . Hanger portion 26 has a first end 32 which engages a portion of front wall 22 b of gutter 22 . First end 32 has a vertical wall 32 a and an inward wall 32 b . Inward wall 32 b is angled inward, toward vertical portion 28 , and slightly upward. As shown in FIGS. 1 and 2 , inward wall 32 b engages a lip 22 c of front wall 22 b , and is disposed between said lip 22 c and the inner surface of front wall 22 b . Likewise, vertical wall 32 a is disposed along the inner surface of front wall 22 b , along a portion thereof.
Referring to FIG. 3 , hanger portion 26 of gutter hanger 12 has a second end 34 disposed on the opposite end of hanger portion 26 from first end 32 . Second end 34 has a vertical wall 34 a extending upward and a hanging portion 34 b . Hanging portion 34 b extends downward from vertical wall 34 a , and extends parallel to vertical wall 34 a for a slight distance, forming a cavity for receiving the hanging portion 14 d and end portion 14 e of gutter clip 14 , which is attached to rear wall 22 a of gutter 22 . An intermediate section 36 of hanger portion 26 is disposed between first end 32 and second end 34 , forming a contiguous hanger portion 26 . Intermediate section 36 is disposed across and inside gutter 22 . Referring to FIGS. 1 and 2 , once second end 34 receives hanging portion 14 d and end portion 14 e of gutter clip 14 , second end 34 of gutter hanger 12 may be crimped using pliers or other suitable crimping devices to secure gutter hanger 12 to gutter clip 14 , and thus, gutter 22 . Once secured, second end 34 is inserted into a cavity between hook portion 16 c and vertical portion 16 a of retaining member 16 . Second end 34 fits tightly within the cavity between hook portion 16 c and vertical portion 16 a to allow retaining member 16 to securely hold gutter 22 , gutter hanger 12 and gutter clip 14 .
Returning to FIG. 3 , vertical portion 28 extends generally upward from intermediate section 36 , and terminates at top portion 30 . As shown, vertical portion 28 has a lower section 28 a that extends generally upward and outward toward a front section 30 b of top portion 30 . An upper section 28 b of vertical portion 28 is adjacent lower section 28 a and extends vertically from lower section 28 a . Upper section 28 b is substantially perpendicular to a rear section 30 a of top portion 30 and intermediate section 36 . A platform 36 a is contiguous with and elevated above intermediate section 36 . On one end of the platform 36 a , a small vertical wall 36 b extends vertically slightly above platform 36 a . On the opposite end, platform 36 a adjoins lower section 28 a of vertical portion 28 . Platform 36 a is disposed between first end 32 of hanger portion 26 and vertical portion 28 .
Front section 30 b of top portion 30 extends outward from rear section 30 a , and angles downward toward first end 32 . An end section 30 c terminates front section 30 b and angles downward and slightly inward from first end 32 . As shown in FIG. 2 , end section 30 c is disposed above first end 32 , rearward of vertical wall 32 a . Rear section 30 a is substantially horizontal and extends rearward from vertical portion 28 . Rear section 30 a terminates in a knob 38 . Top portion 30 as shown accommodates and supports a “nose forward” leaf protection device, as is commonly known in the art. However, top portion 30 could be designed to accommodate other types of leaf protection devices.
Referring to FIGS. 1 , 2 and 3 , once second end 34 is secured within retaining member 16 between hook portion 16 c and vertical portion 16 a , the leaf protection device 24 may be installed. Prior to installing leaf protection device 24 , a support strap 40 is removably attached to top portion 30 . Referring to FIG. 10 , support strap 40 has a clip 40 a on one end thereof which receives knob 38 of rear section 30 a . Clip 40 a snaps onto knob 38 . Support strap 40 extends rearward and contacts a roof of the building, and is attached thereto by a screw 20 , nails (not shown), or other appropriate attaching devices. Support strap 40 aids in relieving stress placed on top portion 30 and vertical portion 28 by leaf protection device 24 . Knob 38 is shown as being “C” shaped or semicircular, and clip 40 a of support strap 40 is shaped correspondingly to receive knob 38 . The semicircular design of knob 38 and clip 40 a allow support strap 40 to rotate vertically, thus allowing support strap to attach to roofs of varying pitches. However, alternatively, support strap 40 could be eliminated, and leaf protection device 24 could be placed directly on top portion 30 without having support strap 40 anchoring top portion 30 to the roof.
Referring to FIG. 2 , leaf protection device 24 is placed over top portion 30 . Nose portion 24 a of leaf protection device 24 substantially conforms to the shape of front section 30 b of top portion 30 . Nose portion 24 a extends over end portion 30 c of front portion 30 b and extends downward and inward toward platform 36 a of intermediate section 36 . There is a gap G between lip 22 c of gutter 22 and leaf protection device 24 , thus allowing the entry of water into gutter 22 while substantially preventing leaves and other debris from entering gutter 22 . A base 24 b of leaf protection device 24 rests on platform 36 a and is prevented from sliding laterally off of platform 36 a by vertical portion 28 and vertical wall 36 b . By providing platform 36 a to receive base 24 b , the weight of nose portion 24 a on front section 30 b is reduced, thus reducing the stress load on front section 30 b . Body portion 24 c of leaf protection device 24 extends toward the roof of the building, covering rear section 30 a , knob 38 , and support strap 40 . A screw 20 is placed through body 24 c and into the roof of the building to secure leaf protection device 24 to the building. Likewise, a screw 20 may optionally be placed through body portion 24 c and rear section 30 a of top portion 30 to further secure leaf protection device to gutter hanger 12 .
Referring now to FIGS. 4 through 7 , an alternative embodiment of the present invention is disclosed. Referring to FIGS. 4 and 5 , in the alternative embodiment, gutter hanger 12 is constructed such that vertical portion 28 is separate, but attachable to hanger portion 26 . Vertical portion 28 has lower section 28 a and upper section 28 b which terminates at top portion 30 . Thus, vertical portion 28 and top portion 30 are constructed of a single piece. Lower section 28 a terminates at platform 36 a . However, platform 36 a is not contiguous with intermediate section 36 of hanger portion 26 . Instead, there is a receiving surface 36 c on which platform 36 a rests when vertical portion 28 is attached to hanger portion 26 . Receiving surface 36 c is elevated above, but contiguous with intermediate section 36 . Serrated walls 36 e extend vertically downward from receiving surface 36 c and are contiguous with intermediate section 36 and receiving surface 36 c . Serrated walls 36 e are serrated on their outer surfaces. Corresponding serrated walls 36 d extend vertically downward from platform 36 a . Serrated walls 36 d are serrated on the inner surfaces such that serrated walls 36 d receive serrated walls 36 e and the serrations of each serrated wall 36 d and 36 e engage to attach vertical portion 28 to hanger portion 26 .
The advantage of having an alternative embodiment wherein gutter hanger 12 is constructed in two separate attachable pieces, as described hereinabove, is shown in FIGS. 6 and 7 . The hanger portion 26 can readily be installed in the gutter system 10 , as described herein. However, if it is not desired to install a leaf protection device 24 , there is no need to install vertical portion 28 and top portion 30 . An advantage of the alternative embodiment is that if it is later desired to add a leaf protection device 24 to the gutter system 10 wherein hanger portion 26 is already installed, vertical portion 28 can be easily snapped onto hanger portion 26 , allowing leaf protection device 24 to be installed on top of the gutter system 10 as described herein, without the need to remove the gutter 22 , gutter clip 14 and hanging portion 26 from the retaining member 16 to replace hanging portion 26 with a one piece gutter hanger 12 .
Referring to FIGS. 11 and 12 , another alternative embodiment of the present invention is disclosed. Gutter hanger 12 is constructed such that vertical portion 28 is separate, but attachable to hanger portion 26 in the same manner as disclosed hereinabove in reference to the embodiment of gutter hanger 12 shown in FIGS. 4 through 7 . However, in the embodiment shown in FIGS. 11 and 12 , a backstop 36 f extends vertically from platform 36 a , and curves slightly forward toward vertical wall 36 b . As shown in FIG. 12 , base 24 b of leaf protection device 24 is inserted between backstop 36 f and vertical wall 36 b and rests there between. The slight forward curvature of backstop 36 f prevents base 24 b from sliding out of the space between backstop 36 f and vertical wall 36 b.
Backstop 36 f is shown as being disposed approximately half way between lower section 28 a of vertical portion 28 and vertical wall 36 b . However, backstop 36 f could be placed at any position along platform 36 a between lower section 28 a and vertical wall 36 b so long as the distance between backstop 36 f and vertical wall 36 b is sufficient to receive base 24 b of leaf protection device 24 . Furthermore, although gutter hanger 12 is shown the embodiment disclosed in FIGS. 11 and 12 as having vertical portion 28 separate but attachable to hanger portion 26 , gutter hanger 12 having backstop 36 f could be comprised of a single piece, as disclosed in FIGS. 1 through 3 .
Although the invention has been described with reference to specific embodiments, this description is not meant to be construed in a limited sense. Various modifications of the disclosed embodiments, as well as alternative embodiments of the invention will become apparent to persons skilled in the art upon the reference to the description of the invention. It is, therefore, contemplated that the appended claims will cover such modifications that fall within the scope of the invention. | An interlocking gutter system that incorporates a gutter clip and a gutter hanger to affix a gutter to a retaining clip attached to a fascia board of a building, thereby eliminating the need to place holes in the gutter itself to insert screws or nails. The gutter hanger of the present invention is constructed of a single piece which has a hanger portion which is disposed substantially within the gutter and spans the width of the gutter to maintain the shape and structural integrity of the gutter. A vertical portion of the gutter hanger extends vertically from the hanger portion and terminates in a top portion which provides support to a leaf protection device. Alternatively, the gutter hanger is constructed of a hanger portion, and a separate vertical portion which is contiguous with the top portion, and is also removably attachable to the hanger portion. | 4 |
FIELD OF THE INVENTION
This invention relates to the solution polymerization of ethylene in two reactors using two different catalyst systems.
BACKGROUND OF THE INVENTION
The use of so-called “single-site” catalysts such as metallocene catalysts to prepare polyethylene having a narrow molecular weight distribution is well known. The “linear low density polyethylene” (or “LLDPE”, a copolymer of ethylene and a higher alpha olefin) prepared with such catalysts typically exhibits a very uniform composition distribution (i.e. the comonomer is very uniformly distributed within the polymer chains). The combination of narrow molecular weight distribution and uniform composition distribution distinguishes these polymers from “conventional” LLDPE which is commercially manufactured with a Ziegler Natta catalyst or a chromium catalyst. In particular, the conventional LLDPE products have a broader molecular weight distribution and a broader composition distribution. These compositional differences are manifested in the form of differences in the physical properties of the two types of LLDPE polymers. Most notably, LLDPE prepared with a single site catalyst has improved impact strength and optical properties in comparison to “conventional” LLDPE. However, one advantage of the “conventional” LLDPE is that it is usually easier to “process” in its existing mixers and extruders. Accordingly, it would be highly desirable to prepare LLDPE products which possess the improved physical properties offered by single site catalysts and retain the broad molecular weight distribution (for improved processability) which is associated with conventional LLDPE.
One approach which has been used to achieve this object is the use of mixed catalyst systems. For example, U.S. Pat. No. (USP) 4,530,914 (Ewen et al, to Exxon) teaches the use of two different metallocenes and U.S. Pat. No. 4,701,432 (Welborn, to Exxon) teaches the use of a supported catalyst prepared with a metallocene catalyst and a Ziegler Natta catalyst. Many others have subsequently attempted to use similar mixed catalyst systems as may be quickly ascertained by reviewing the patent literature.
However, the use of “mixed” catalyst systems is often associated with operability problems. For example, the use of two catalysts on a single support (as taught by Welborn in U.S. Pat. No. 4,701,432) may be associated with a reduced degree of process control flexibility (e.g. If the polymerization reaction is not proceeding as desired when using such a catalyst system, it is difficult to establish which corrective action should be taken as the corrective action will typically have a different effect on each of the two different catalyst components). Moreover, the two different catalyst/cocatalyst systems may interfere with one another—for example, the organoaluminum component which is often used in Ziegler Natta or chromium catalyst systems may “poison” a metallocene catalyst. Accordingly, a “mixed catalyst” process which mitigates some of these difficulties would be a useful addition to the art.
SUMMARY OF THE INVENTION
The present invention provides a medium pressure solution polymerization process characterized by:
A) polymerizing ethylene, optionally with one or more C 3-12 alpha olefins, in solvent in a first polymerization reactor at a temperature of from 80 to 200° C. and a pressure of from 500 to 8,000 pounds per square inch gauge (“psi”) in the presence of (a) a first catalyst which is an organometallic complex of a group 4 or 5 metal that is characterized by having at least one phosphinimine ligand; and (b) a first cocatalyst; and
B) passing said first polymer solution into a second polymerization reactor and polymerizing ethylene, optionally with one or more C 3-12 alpha olefins, in said second stirred polymerization reactor at a higher polymerization temperature than that of said first reactor in the presence of a Ziegler Natta catalyst, wherein said Ziegler Natta catalyst comprises a transition metal compound of a transition metal selected from groups 3, 4 or 5 of the Periodic Table (using IUPAC nomenclature) and an organoaluminum component which is defined by the formula:
Al(X′) a (OR) b (R) c
wherein: X′ is a halide (preferably chlorine); OR is an alkoxy or aryloxy group; R is a hydrocarbyl (preferably an alkyl having from 1 to 10 carbon atoms); and a, b, or c are each 0, 1, 2 or 3 with the provisos that a+b+c=3 and b+c≧1.
Thus, the process of the present invention requires two solution polymerization reactors and two distinct catalyst systems. The first catalyst must have a phosphinimine ligand (and, hence, is sometimes referred to herein as a “phosphinimine catalyst” or “PIC”).
The first reactor uses the “phosphinimine catalyst”. Conventional process control techniques may be used to operate the first reactor as there is only one catalyst to deal with.
Preferred phosphinimine catalysts for use in the first reactor are titanium species which contain one cyclopentadienyl ligand, one phosphinimine ligand and two chloride ligands.
It is particularly preferred that the concentration of titanium in the first reactor be less that 1 part per million (ppm) especially less that 0.5 ppm (based on the weight of titanium divided by the weight of the reactor contents).
Exemplary cocatalysts for the phosphinimine catalyst are alumoxanes and/or ionic activators. Preferred cocatalysts for the phosphinimine catalyst are a combination of:
1) an alumoxane (in which the Al/Ti molar ratio, based on the alumoxane and the titanium in the phosphinimine catalyst is between 10/1 and 200/1, most preferably from 40/1 to 120/1); and
2) a boron-containing ionic activator (in which the B/Ti ratio, based on the boron in the ionic activator to the titanium in the phosphinimine catalyst is between 0.5/1 and 1.5/1).
The polymer solution from the first reactor is transferred to the second solution polymerization reactor. A Ziegler Natta catalyst is used in the second reactor. It is preferred that the Ziegler Natta catalyst contains at least one transition metal selected from titanium and vanadium, and that the molar concentration of titanium/vanadium which is added to the second reactor is at least 10 times greater than the titanium concentration in the first reactor.
Thus, the second polymerization reactor must use a Ziegler Natta catalyst. Additionally, the second polymerization reactor must be operated at a higher temperature from the first—most preferably, at least 30° C. higher than the first.
While not wishing to be bound by any particular theory, it is believed that the reactor conditions in the second reactor “overwhelm” the catalyst from the first reactor (i.e. for process control purposes, any residual catalyst from the first reactor is not a concern in the second reactor). This is desirable from a process operability perspective as it reduces the number of variables which need to be considered when controlling the polymerization reaction in the second reactor.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Part 1. Description of First Catalysts
The catalyst used in the first reactor of the process of this invention (“first catalyst”) is an organometallic complex of a group 4 or 5 metal which is characterized by having at least one phosphinimine ligand (where the term phosphinimine is defined in section 1.2 below).
Any such organometallic having a phosphinimine ligand which displays catalytic activity for ethylene polymerization may be employed. Preferred first catalysts are defined by the formula:
wherein M is a transition metal selected from Ti, Hf and Zr (as described in section 1.1 below); Pl is a phosphinimine ligand (as described in section 1.2 below); L is a monanionic ligand which is a cyclopentadienyl-type ligand or a bulky heteroatom ligand (as described in section 1.3 below); X is an activatable ligand which is most preferably a simple monanionic ligand such as alkyl or a halide (as described in section 1.4 below); m is 1 or 2, n is 0 or 1, and p is fixed by the valence of the metal M.
The most preferred first catalysts are group 4 metal complexes in the highest oxidation state. For example, a preferred catalyst may be a bis (phosphinimine) dichloride complex of titanium, zirconium or hafnium. However, it is particularly preferred that the first catalyst contain one phosphinimine ligand, one “L” ligand (which is most preferably a cyclopentadienyl-type ligand) and two “X” ligands (which are preferably both chloride).
1.1 Metals
The first catalyst is an organometallic complex of a group 4 or 5 metal (where the numbers refer to columns in the Periodic Table of the Elements using IUPAC nomenclature). The preferred metals are from group 4, (especially titanium, hafnium or zirconium) with titanium being most preferred.
1.2 Phosphinimine Ligand
The first catalyst must contain a phosphinimine ligand which is covalently bonded to the metal. This ligand is defined by the formula:
wherein each R 1 is independently selected from the group consisting of a hydrogen atom, a halogen atom, C 1-20 hydrocarbyl radicals which are unsubstituted by or further substituted by a halogen atom, a C 1-8 alkoxy radical, a C 6-10 aryl or aryloxy radical, an amido radical, and a silyl radical of the formula:
—Si—(R 2 ) 3
wherein each R 2 is independently selected from the group consisting of hydrogen, a C 1-8 alkyl or alkoxy radical, C 6-10 aryl or aryloxy radicals, and a germanyl radical of the formula:
Ge—(R 2 ) 3
wherein R 2 is as defined above.
The preferred phosphinimines are those in which each R 1 is a hydrocarbyl radical. A particularly preferred phosphinimine is tri-(tertiary butyl) phosphinimine (i.e. where each R 1 is a tertiary butyl group).
1.3 Ligand L
Preferred first catalysts are group 4 organometallic complexes which contain one phosphinimine ligand (as described in section 1.2 above) and one ligand L (as described in sections 1.3.1 to 1.3.6) which is either a cyclopentadienyl-type ligand or a heteroligand.
1.3.1 Cyclopentadienyl-type Ligands
As used herein, the term cyclopentadienyl-type ligand is meant to convey its conventional meaning, namely a ligand having a five carbon ring which is bonded to the metal via eta-5 bonding. Thus, the term “cyclopentadienyl-type” includes unsubstituted cyclopentadienyl, substituted cyclopentadienyl, unsubstituted indenyl, substituted indenyl, unsubstituted fluorenyl and substituted fluorenyl. An exemplary list of substituents for a cyclopentadienyl ligand includes the group consisting of C 1-10 hydrocarbyl radical (which hydrocarbyl substituents are unsubstituted or further substituted); a halogen atom, C 1-8 alkoxy radical, a C 6-10 aryl or aryloxy radical; an amido radical which is unsubstituted or substituted by up to two C 1-8 alkyl radicals; a phosphido radical which is unsubstituted or substituted by up to two C 1-8 alkyl radicals; silyl radicals of the formula —Si—(R) 3 wherein each R is independently selected from the group consisting of hydrogen, a C 1-8 alkyl or alkoxy radical C 6-10 aryl or aryloxy radicals; germanyl radicals of the formula Ge—(R 2 ) 3 wherein R is as defined directly above.
1.3.2 Heteroligand
As used herein, the term “heteroligand” refers to a ligand which contains at least one heteroatom selected from the group consisting of boron, nitrogen, oxygen, phosphorus or sulfur. The heteroligand may be sigma or pi-bonded to the metal. Exemplary heteroligands are described in sections 1.3.2.1 to 1.3.2.6 below.
1.3.2.1 Ketimide Ligands
As used herein, the term “ketimide ligand” refers to a ligand which: (a) is bonded to the transition metal via a metal-nitrogen atom bond; (b) has a single substituent on the nitrogen atom, (where this single substituent is a carbon atom which is doubly bonded to the N atom); and (c) has two substituents (Sub 1 and Sub 2, described below) which are bonded to the carbon atom.
Conditions a, b and c are illustrated below:
The substituents “Sub 1 and Sub 2” may be the same or different. Exemplary substituents include hydrocarbyls having from 1 to 20 carbon atoms; silyl groups, amido groups and phosphido groups. For reasons of cost and convenience it is preferred that these substituents both be hydrocarbyls, especially simple alkyls and most preferably tertiary butyl.
1.3.2.2 Silicone-Containing Heteroligands
These ligands are defined by the formula:
—(μ)SiR x R y R z
where the—denotes a bond to the transition metal and μ is sulfur or oxygen.
The substituents on the Si atom, namely R x , R y and R z are required in order to satisfy the bonding orbital of the Si atom. The use of any particular substituent R x , R y or R z is not especially important to the success of this invention. It is preferred that each of R x , R y and R z is a C 1-2 hydrocarbyl group (i.e. methyl or ethyl) simply because such materials are readily synthesized from commercially available materials).
1.3.2.3 Amido Ligands
The term “amido” is meant to convey its broad, conventional meaning. Thus, these ligands are characterized by (a) a metal-nitrogen bond, and (b) the presence of two substituents (which are typically simple alkyl or silyl groups) on the nitrogen atom.
1.3.2.4 Alkoxy Ligands
The term “alkoxy” is also intended to convey its conventional meaning. Thus, these ligands are characterized by (a) a metal oxygen bond, and (b) the presence of a hydrocarbyl group bonded to the oxygen atom. The hydrocarbyl group may be a ring structure and/or substituted (e.g. 2, 6 di-tertiary butyl phenoxy).
1.3.2.5 Boron Heterocyclic Ligands
These ligands are characterized by the presence of a boron atom in a closed ring ligand. This definition includes heterocyclic ligands which also contain a nitrogen atom in the ring. These ligands are well known to those skilled in the art of olefin polymerization and are fully described in the literature (see, for example, U.S. Pat. Nos. 5,637,659; 5,554,775 and the references cited therein).
1.3.2.6 Phosphole Ligands
The term “phosphole” is also meant to convey its conventional meaning. “Phospholes” are cyclic dienyl structures having four carbon atoms and one phosphorus atom in the closed ring. The simplest phosphole is C 4 Ph 4 (which is analogous to cyclopentadiene with one carbon in the ring being replaced by phosphorus). The phosphole ligands may be substituted with, for example, C 1-20 hydrocarbyl radicals (which may, optionally, contain halogen substituents); phosphido radicals; amido radicals; silyl or alkoxy radicals. Phosphole ligands are also well known to those skilled in the art of olefin polymerization and are described as such in U.S. Pat. No. 5,434,116.
1.4 Activatable Ligand
The term “activatable ligand” refers to a ligand which may be activated by a cocatalyst, (also referred to as an “activator”), to facilitate olefin polymerization. Exemplary activatable ligands are independently selected from the group consisting of a hydrogen atom, a halogen atom, a C 1-10 hydrocarbyl radical, a C 1-10 alkoxy radical, a C 5-10 aryl oxide radical; each of which said hydrocarbyl, alkoxy, and aryl oxide radicals may be unsubstituted by or further substituted by a halogen atom, a C 1-8 alkyl radical, a C 1-8 alkoxy radical, a C 6-10 aryl or aryloxy radical, an amido radical which is unsubstituted or substituted by up to two C 1-8 alkyl radicals; a phosphido radical which is unsubstituted or substituted by up to two C 1-8 alkyl radicals.
The number of activatable ligands depends upon the valency of the metal and the valency of the activatable ligand. The preferred first catalyst metals are group 4 metals in their highest oxidation state (i.e. 4 + ) and the preferred activatable ligands are monoanionic (such as a halide—especially chloride or a alkyl—especially methyl). Thus, the preferred first catalyst contains a phosphinimine ligand, a cyclopentadienyl ligand and two chloride (or methyl) ligands bonded to the group 4 metal. In some instances, the metal of the first catalyst component may not be in the highest oxidation state. For example, a titanium (III) component would contain only one activatable ligand.
1.5 Summary Description of Preferred Catalyst
As previously noted, the preferred first catalyst is a group 4 organometallic complex in its highest oxidation state having a phosphinimine ligand, a cyclopentadienyl-type ligand and two activatable ligands. These requirements may be concisely described using the following formula for the preferred catalyst:
wherein: (a) M is a metal selected from Ti, Hf and Zr; (b) Pl is a phosphinimine ligand defined by the formula:
wherein each R 1 is independently selected from the group consisting of a hydrogen atom, a halogen atom, C 1-20 hydrocarbyl radicals which are unsubstituted by or further substituted by a halogen atom, a C 1-8 alkoxy radical, a C 6-10 aryl or aryloxy radical, an amido radical, a silyl radical of the formula:
—Si—(R 2 ) 3
wherein each R 2 is independently selected from the group consisting of hydrogen, a C 1-8 alkyl or alkoxy radical, C 6-10 aryl or aryloxy radicals, and a germanyl radical of the formula:
Ge—(R 2 ) 3
wherein R 2 is as defined above; (c) L is a ligand selected from the group consisting of cyclopentadienyl, substituted cyclopentadienyl, indenyl, substituted indenyl, fluorenyl, or substituted fluorenyl; and (d) X is an activatable ligand, and wherein: m is 1, n is 1 and p is 2.
2. Description of First Cocatalyst
The catalyst components described in part 1 above are used in combination with at least one cocatalyst (or “activator”) to form an active catalyst system for olefin polymerization as described in more detail in sections 2.1, 2.2 and 2.3 below.
2.1 Alumoxanes
The alumoxane may be of the formula:
(R 4 ) 2 AlO(R 4 AlO) m Al(R 4 ) 2
wherein each R 4 is independently selected from the group consisting of C 1-20 hydrocarbyl radicals and m is from 0 to 50, preferably R 4 is a C 1-4 alkyl radical and m is from 5 to 30. Methylalumoxane (or “MAO”) in which each R is methyl is the preferred alumoxane.
Alumoxanes are well known as cocatalysts, particularly for metallocene-type catalysts. Alumoxanes are also readily available articles of commerce.
The use of an alumoxane cocatalyst generally requires a molar ratio of aluminum to the transition metal in the catalyst from 20:1 to 1000:1. Preferred ratios are from 50:1 to 250:1.
2.2 “Ionic Activators” as Cocatalysts
So-called “ionic activators” are also well known for metallocene catalysts. See, for example, U.S. Pat. No. 5,198,401 (Hlatky and Turner) and U.S. Pat No. 5,132,380 (Stevens and Neithamer).
Whilst not wishing to be bound by any theory, it is thought by those skilled in the art that “ionic activators” initially cause the abstraction of one or more of the activatable ligands in a manner which ionizes the catalyst into a cation, then provides a bulky, labile, non-coordinating anion which stabilizes the catalyst in a cationic form. The bulky, non-coordinating anion coordinating anion permits olefin polymerization to proceed at the cationic catalyst center (presumably because the non-coordinating anion is sufficiently labile to be displaced by monomer which coordinate to the catalyst). Preferred ionic activators are boron-containing ionic activators described in (i)-(iii) below:
(i) compounds of the formula [R 5 ] + [B(R 7 ) 4 ] − wherein B is a boron atom, R 5 is a aromatic hydrocarbyl (e.g. triphenyl methyl cation) and each R 7 is independently selected from the group consisting of phenyl radicals which are unsubstituted or substituted with from 3 to 5 substituents selected from the group consisting of a fluorine atom, a C 1-4 alkyl or alkoxy radical which is unsubstituted or substituted by a fluorine atom; and a silyl radical of the formula —Si—(R 9 ) 3 ; wherein each R 9 is independently selected from the group consisting of a hydrogen atom and a C 1-4 alkyl radical; and
(ii) compounds of the formula [(R 8 ) t ZH] + [B(R 7 ) 4 ] − wherein B is a boron atom, H is a hydrogen atom, Z is a nitrogen atom or phosphorus atom, t is 2 or 3 and R 8 is selected from the group consisting of C 1-8 alkyl radicals, a phenyl radical which is unsubstituted or substituted by up to three C 1-4 alkyl radicals, or one R 8 taken together with the nitrogen atom may form an anilinium radical and R 7 is as defined above; and
(iii) compounds of the formula B(R 7 ) 3 wherein R 7 is as defined above.
In the above compounds preferably R 7 is a pentafluorophenyl radical, and R 5 is a triphenylmethyl cation, Z is a nitrogen atom and R 8 is a C 1-4 alkyl radical or R 8 taken together with the nitrogen atom forms an anilium radical which is substituted by two C 1-4 alkyl radicals.
The “ionic activator” may abstract one or more activatable ligands so as to ionize the catalyst center into a cation but not to covalently bond with the catalyst and to provide sufficient distance between the catalyst and the ionizing activator to permit a polymerizable olefin to enter the resulting active site.
Examples of ionic activators include:
triethylammonium tetra(phenyl)boron,
tripropylammonium tetra(phenyl)boron,
tri(n-butyl)ammonium tetra(phenyl)boron,
trimethylammonium tetra(p-tolyl)boron,
trimethylammonium tetra(o-tolyl)boron,
tributylammonium tetra(pentafluorophenyl)boron,
tripropylammonium tetra(o,p-dimethylphenyl)boron,
tributylammonium tetra(m,m-dimethylphenyl)boron,
tributylammonium tetra(p-trifluoromethylphenyl)boron,
tributylammonium tetra(pentafluorophenyl)boron,
tri(n-butyl)ammonium tetra(o-tolyl)boron,
N,N-dimethylanilinium tetra(phenyl)boron,
N,N-diethylanilinium tetra(phenyl)boron,
N,N-diethylanilinium tetra(phenyl)n-butylboron,
N,N-2,4,6-pentamethylanilinium tetra(phenyl)boron,
di-(isopropyl)ammonium tetra(pentafluorophenyl)boron,
dicyclohexylammonium tetra(phenyl)boron,
triphenylphosphonium tetra(phenyl)boron,
tri(methylphenyl)phosphonium tetra(phenyl)boron,
tri(dimethylphenyl)phosphonium tetra(phenyl )boron,
tropillium tetrakispentafluorophenyl borate,
triphenylmethylium tetrakispentafluorophenyl borate,
benzene (diazonium) tetrakispentafluorophenyl borate,
tropillium phenyltrispentafluorophenyl borate,
triphenylmethylium phenyltrispentafluorophenyl borate,
benzene (diazonium) phenyltrispentafluorophenyl borate,
tropillium tetrakis (2,3,5,6-tetrafluorophenyl) borate,
triphenylmethylium tetrakis (2,3,5,6-tetrafluorophenyl) borate,
benzene (diazonium) tetrakis (3,4,5-trifluorophenyl) borate,
tropillium tetrakis (3,4,5-trifluorophenyl) borate,
benzene (diazonium) tetrakis (3,4,5-trifluorophenyl) borate,
tropillium tetrakis (1,2,2-trifluoroethenyl) borate,
triphenylmethylium tetrakis (1,2,2-trifluoroethenyl) borate,
benzene (diazonium) tetrakis (1,2,2-trifluoroethenyl) borate,
tropillium tetrakis (2,3,4,5-tetrafluorophenyl) borate,
triphenylmethylium tetrakis (2,3,4,5-tetrafluorophenyl) borate, and
benzene (diazonium) tetrakis (2,3,4,5-tetrafluorophenyl) borate.
Readily commercially available ionic activators include:
N,N-dimethylaniliniumtetrakispentafluorophenyl borate;
triphenylmethylium tetrakispentafluorophenyl borate; and
trispentafluorophenyl borane.
3. Description of Ziegler Natta Catalyst
The term “Ziegler Natta catalyst” is well known to those skilled in the art and is used herein to convey its conventional meaning. A Ziegler Natta catalyst must be used in the second (hot) reactor of this invention. Ziegler Natta catalysts comprise at least one transition metal compound of a transition metal selected from groups 3, 4, or 5 of the Periodic Table (using IUPAC nomenclature) and an organoaluminum component which is defined by the formula:
Al(X′) a (OR) b (R) c
wherein: X′ is a halide (preferably chlorine); OR is an alkoxy or aryloxy group; R is a hydrocarbyl (preferably an alkyl having from 1 to 10 carbon atoms); and a,b, or c are each 0, 1, 2, or 3 with the provisos text a+b+c=3 and b+c≧1.
It is highly preferred that the transition metal compounds contain at least one of titanium or vanadium. Exemplary titanium compounds include titanium halides (especially titanium chlorides, of which TiCl 4 is preferred); titanium alkyls; titanium alkoxides (which may be prepared by reacting a titanium alkyl with an alcohol) and “mixed ligand” compounds (i.e. compounds which contain more than one of the above described halide, alkyl and alkoxide ligands). Exemplary vanadium compounds may also contain halide, alkyl or alkoxide ligands. In addition vanadium oxy trichloride (“VOCl 3 ”) is known as a Ziegler Natta catalyst component and is suitable for use in the present invention.
It is especially preferred that the Ziegler Natta catalyst contain both of a titanium and a vanadium compound. The Ti/V mole ratios may be from 10/90 to 90/10, with mole ratios between 50/50 and 20/80 being particularly preferred.
The above defined organoaluminum compound is an essential component of the Ziegler Natta catalyst. The mole ratio of aluminum to transition metal {for example, aluminum/(titanium+vanadium)} is preferably from 1/1 to 100/1, especially from 1.2/1 to 15/1.
As will be appreciated by those skilled in the art of ethylene polymerization, conventional Ziegler Natta catalysts may also incorporate additional components such as an electron donor—for example an amine; or a magnesium compound—for example a magnesium alkyl such as butyl ethyl magnesium and a halide source (which is typically a chloride such as tertiary butyl chloride).
Such components, if employed, may be added to the other catalyst components prior to introduction to the reactor or may be directly added to the reactor.
The Ziegler Natta catalyst may also be “tempered” (i.e. heat treated) prior to being introduced to the reactor (again, using techniques which are well known to those skilled in the art and published in the literature).
4. Description of Dual Reactor Solution Polymerization Process
Solution processes for the (co)polymerization of ethylene are well known in the art. These processes are conducted in the presence of an inert hydrocarbon solvent typically a C 5-12 hydrocarbon which may be unsubstituted or substituted by a C 1-4 alkyl group, such as pentane, methyl pentane, hexane, heptane, octane, cyclohexane, methycyclohexane and hydrogenated naphtha. An example of a suitable solvent which is commercially available is “Isopar E” (C 8-12 aliphatic solvent, Exxon Chemical Co.).
The solution polymerization process of this invention must use at least two polymerization reactors. The first polymerization reactor must operate at a lower temperature (“cold reactor”) using a “phosphinimine catalyst” described in Part 1 above.
The polymerization temperature in the first reactor is from about 80° C. to about 180° C. (preferably from about 120° C. to 160° C.) and the hot reactor is preferably operated at a higher temperature (up to about 300° C.). Both reactors are preferably “stirred reactors” (i.e. the reactors are well mixed with a good agitation system). Preferred pressures are from about 500 psi to 8,000 psi. The most preferred reaction process is a “medium pressure process”, meaning that the pressure in each reactor is preferably less than about 6,000 psi (about 42,000 kiloPascals or kPa), most preferably from about 1,500 psi to 3,000 psi (about 14,000-22,000 kPa)
Suitable monomers for copolymerization with ethylene include C 3-20 mono- and di-olefins. Preferred comonomers include C 3-12 alpha olefins which are unsubstituted or substituted by up to two C 1-6 alkyl radicals, C 8-12 vinyl aromatic monomers which are unsubstituted or substituted by up to two substituents selected from the group consisting of C 1-4 alkyl radicals, C 4-12 straight chained or cyclic diolefins which are unsubstituted or substituted by a C 1-4 alkyl radical. Illustrative non-limiting examples of such alpha-olefins are one or more of propylene, 1-butene, 1-pentene, 1-hexene, 1-octene, and 1-decene, styrene, alpha methyl styrene and the constrained-ring cyclic olefins such as cyclobutene, cyclopentene, dicyclopentadiene norbornene, alkyl-substituted norbornes, alkenyl-substituted norbornes and the like (e.g. 5-methylene-2-norbornene and 5-ethylidene-2-norbornene, bicyclo-(2,2,1)-hepta-2,5-diene).
The polyethylene polymers which may be prepared in accordance with the present invention are LLDPE's which typically comprise not less than 60, preferably not less than 75 weight % of ethylene and the balance one or more C 4-10 alpha olefins, preferably selected from the group consisting of 1-butene, 1-hexene and 1-octene. The polyethylene prepared in accordance with the present invention may be LLDPE having a density from about 0.910 to 0.935 g/cc or (linear) high density polyethylene having a density above 0.935 g/cc. The present invention might also be useful to prepare polyethylene having a density below 0.910 g/cc—the so-called very low density polyethylene and ultra low density polyethylenes (or “plastomers”).
Generally the alpha olefin may be present in an amount from about 3 to 30 weight %, preferably from about 4 to 25 weight %.
The present invention may also be used to prepare co- and ter-polymers of ethylene, propylene and optionally one or more diene monomers. Generally, such polymers will contain about 50 to about 75 weight % ethylene, preferably about 50 to 60 weight % ethylene and correspondingly from 50 to 25 weight % of propylene. A portion of the monomers, typically the propylene monomer, may be replaced by a conjugated diolefin. The diolefin may be present in amounts up to 10 weight % of the polymer although typically is present in amounts from about 3 to 5 weight %. The resulting polymer may have a composition comprising from 40 to 75 weight % of ethylene, from 50 to 15 weight % of propylene and up to 10 weight % of a diene monomer to provide 100 weight % of the polymer. Preferred but not limiting examples of the dienes are dicyclopentadiene, 1,4-hexadiene, 5-methylene-2-norbornene, 5-ethylidene-2-norbornene and 5-vinyl-2-norbornene, especially 5-ethylidene-2-norbornene and 1,4-hexadiene.
The monomers are dissolved/dispersed in the solvent either prior to being fed to the first reactor (or for gaseous monomers the monomer may be fed to the reactor so that it will dissolve in the reaction mixture). Prior to mixing, the solvent and monomers are generally purified to remove potential catalyst poisons such as water, oxygen or metal impurities. The feedstock purification follows standard practices in the art, e.g. molecular sieves, alumina beds and oxygen removal catalysts are used for the purification of monomers. The solvent itself as well (e.g. methyl pentane, cyclohexane, hexane or toluene) is preferably treated in a similar manner.
The feedstock may be heated or cooled prior to feeding to the first reactor. Additional monomers and solvent may be added to the second reactor, and it may be heated or cooled.
Generally, the catalyst components may be premixed in the solvent for the reaction or fed as separate streams to each reactor. In some instances premixing it may be desirable to provide a reaction time for the catalyst components prior to entering the reaction. Such an “in line mixing” technique is described in a number of patents in the name of DuPont Canada Inc (e.g. U.S. Pat. No. 5,589,555, issued Dec. 31, 1996).
The residence time in each reactor will depend on the design and the capacity of the reactor. Generally the reactors should be operated under conditions to achieve a thorough mixing of the reactants. In addition, it is preferred that from 20 to 60 weight % of the final polymer is polymerized in the first reactor, with the balance being polymerized in the second reactor. In a highly preferred embodiment, the first polymerization reactor has a smaller volume than the second polymerization reactor. On leaving the reactor system the solvent is removed and the resulting polymer is finished in a conventional manner.
Further details of the invention are illustrated in the following, non limiting, examples.
EXAMPLES
Continuous Solution Polymerization
All the polymerization experiments described below were conducted using a continuous solution polymerization system. The process is continuous in all feed streams (solvent, monomers and catalyst) and in the removal of product. All feed streams were purified prior to the reactors by contact with various absorption media to remove catalyst killing impurities such as water, oxygen and polar materials as is known to those skilled in the art. All components were stored and manipulated under an atmosphere of purified nitrogen.
The polymerization system included two reactors connected in series. The first reactor had an internal volume of 51 mL and was connected via tubing to a second reactor having an internal volume of 71.5 mL. It was possible to add monomers, solvent and/or catalysts to each of the reactors.
The catalyst used in the first reactor was a titanium complex having one cyclopentadienyl ligand, one tri (tertiary butyl) phosphinimine ligand and two chloride ligands (i.e. “CpTi NP( t Bu) 3 Cl 2 ”). This catalyst was used in all inventive experiments and is identified in Table 1 as “PIC” (for phosphinimine catalyst).
The Ziegler Natta catalyst used in the second reactor was a mixed titanium/vanadium system using titanium tetrachloride (“TiCl 4 ”) and vanadium oxy trichloride (“VOCl 3 ”). Triethyl aluminum (“AlEt 3 ”) was used as part of the Ziegler Natta catalyst system.
The cocatalyst used in the first reactor was a combination of a boron-containing ionic activator and an alumoxane. (Note: the ionic activator used in experiments 1,2,3,4,5 and 6 was triphenylmethylium tetrakispentafluorophenyl borate or “Ph 3 CB(C 6 F 5 ) 4 ”. The ionic activator used in the remaining experiments was trispentafluorophenyl borane or “B(C 6 F 5 ) 3 ”. The alumoxane used in all other experiments was a commercially available isobutylaluminoxane sold under the trademark “IBAO-65” by AKZO-Nobel).
Catalysts and cocatalysts used in the first reactor were added independently by way of xylene solutions.
The polymerizations were carried out in cyclohexane at a pressure of about 1,500 pounds per square inch gauge (“psi”). The pressure in the second reactor was slightly lower than that of the first to facilitate transfer of the polymer solution between the reactors. Ethylene was supplied to the reactors by a calibrated thermal mass flow meter and was dissolved in the reaction solvent prior to the polymerization reactor. If comonomer was used it was also premixed with the ethylene before entering the polymerization reactor. Under these conditions the ethylene conversion is a dependent variable controlled by such variables as the catalyst concentration, reaction temperature and catalyst activity.
The internal reactor temperatures were monitored by a thermocouple in the polymerization medium and can be controlled at the required set point to +/−0.50° C. Downstream of the second reactor the pressure was reduced from the reaction pressure (about 1,500 psi) to atmospheric pressure. The solid polymer was then recovered from the discharge of the second reactor as a slurry in the condensed solvent and was dried by evaporation before analysis.
The accompanying tables illustrate flow rates to the reactors, catalyst concentrations and ethylene conversions. The flow rate of ethylene (“C2” in the tables) and octene (“C8” in the tables) is expressed in grams per minute. The monomers were dissolved in solvent and flow rates were adjusted to provide average reactor residence times (also referred to as “hold up times” or “HUT”) of 1.5 minutes in the first reactor and 1.74 minutes in the second reactor (for all experiments). The concentration of catalyst in each reactor is reported on a transition metal basis. Likewise, the mole ratio of cocatalysts (in comparison to the catalysts) is reported for all experiments in the tables.
The ethylene conversions (“Q”, in the tables) in each reactor were determined by gas chromatography. The results are shown in the tables under the heading “%Q-R1” and “%Q-R2” for the first and second reactor, respectively.
The experiments of Table 1 were completed using Ph 3 CB(C 6 F 5 ) 4 as the ionic activator at reactor temperatures of 160° C. in the first reactor and 230° C. in the second reactor.
Table 2 illustrates the effect of using a different ionic activator, namely B(C 6 F 5 ) 3 . The reactor temperatures were again 160° C. for the first reactor and 230° C. for the second reactor.
Table 3 illustrates the effect of using different first reactor temperatures while keeping the second reactor temperature at 230° C. Experiments 1, 2, 4, 5, 7 and 9 are comparative and are provided to illustrate comparative products produced using single reactor/single catalyst systems.
Polymer Analysis
Molecular weights were determined by gel permeation chromatography (“GPC”). GPC analysis was carried out using a Waters 150C GPC using 1,2,4-trichlorobenzene as the mobile phase at 140° C. The samples were prepared by dissolving the polymer in the mobile phase solvent in an external oven at 0.1% (w/v) and were run without filtration. Molecular weights are expressed as polyethylene equivalents with a relative standard deviation of 2.9% and 5.0% for the number average molecular weight “Mn” and weight average molecular weight “Mw” respectively. Molecular weight distribution (“MWD”) is obtained by dividing Mw by Mn.
Melt index (MI) measurements were conducted according to ASTM method D-1238-82.
Polymer densities were measured using pressed plaques (ASTM D-1928-90) with a densitometer.
The amount of comonomer was determined by Fourier transform infra red (“FTIR”) analysis and reported in the tables.
TABLE 1
Dual Reactor, Phosphinimine catalyst to first (cold) reactor and Ziegler-Natta catalyst to the second (hot) reactor
(using trityl borate activator with the single site catalyst)
First Reactor
Second Reactor
PIC/Ph 3 CB(C 6 F 5 ) 4 /IBAO.65
Ziegler-Natta Catalyst
(1/1.2/100 mole ratio)
(Ti/V - 20/80M) - AlEt 3
Polymer Characterization
Run
C2
C8
[Ti]
C2
C8
Al/(Ti&V)
[Ti&V]
Density
Mn ×
Mw ×
Wt. % C8
#
g/min
g/min
μmol/L
% Q-R1
g/min
g/min
Molar
μmol/L
% Q-R2
MI
g/cc
1000
1000
MWD
(FTIR)
1
2.7
0
0.38
90.3
—
—
—
—
—
—
0.9477
76.8
201.5
2.62
—
2
—
—
—
—
2.7
0
2.0
780
89.75
3.76
0.9688
14.4
81.1
5.63
—
3
2.7
0
0.38
—
2.7
0
2.0
780
96.09
0.27
0.9587
28.2
126.9
4.5
—
Ethylene/1-Octene copolymerization
4
2.7
2.14
0.38
—
0
0
0
0
93.14
1.31
0.9227
44.4
87.8
1.98
7.8
5
0
2.14
0
—
2.7
0.43
2.0
976
89.85
48.46
0.9380
6.44
37.8
5.87
11.5
6
2.7
2.14
0.38
—
2.7
0.43
2.0
976
96.56
6.91
0.9280
2.95
63.2
21.42
14
TABLE 2
Dual Reactor, Phosphinimine catalyst to first (cold) reactor and Ziegler-Natta catalyst to the second (hot) reactor
(using tris-borane activator with the single site catalyst)
First Reactor
Second Reactor
PIC/B(C 6 F 5 ) 3 /IBAO-65
Ziegler-Natta Catalyst
(1.0/4.0/50 mole ratio)
(Ti/V - 20/80M) - AlEt 3
Polymer Characterization
Run
C2
C8
[Ti]
C2
C8
Al/(Ti&V)
[Ti&V]
Density
Mn ×
Mw ×
Wt. % C8
#
g/min
g/min
μmol/L
% Q-R1
g/min
g/min
Molar
μmol/L
% Q-R2
MI
g/cc
1000
1000
MWD
(FTIR)
7
2.7
0
1.18
86.02
0
0
0
0
—
—
0.9433
133.0
234.8
1.77
—
8
2.7
0
1.18
—
2.7
0
2.0
780
95.68
0.08
0.9575
25.4
174.9
6.89
—
Ethylene/1-Octene copolymerization
9
2.7
2.14
1.18
86.22
0
0
0
0
—
0.73
0.9212
58.1
98.5
1.70
7.3
10
2.7
2.14
1.18
—
2.7
0.43
2.0
976
97.04
6.20
0.9289
7.65
73.4
9.59
9.3
TABLE 3
Dual Reactor, Phosphinimine catalyst to first (cold) reactor and Ziegler-Natta catalyst to the second (hot) reactor
Effect of first reactor temperature variation.
First Reactor
Second Reactor
PIC/B(C 6 F 5 ) 3 /IBAO-65
Ziegler-Natta Catalyst
(1.0/4.0/50 mole ratio)
(Ti/V - 20/80M) - AlEt 3
Polymer Characterization
Run
C2
C8
[Ti]
Temp
C2
C8
Al/(Ti&V)
[Ti&V]
Density
Mn ×
Mw ×
Wt. % C8
#
g/min
g/min
μmol/L
(R1)
g/min
g/min
Molar
μmol/L
% Q-R2
MI
g/cc
1000
1000
MWD
(FTIR)
10
2.7
2.14
1.18
160
2.7
0.43
2.0
976
97.04
6.2
0.9289
7.65
73.4
9.59
9.3
11
2.2
2.14
1.18
150
2.7
0.43
2.0
976
95.86
5.2
0.9232
7.97
66.2
8.31
10.6
12
2.2
2.14
1.18
140
2.7
0.43
2.0
976
95.63
4.4
0.9196
16
71.8
4.49
11.2 | A dual reactor process for the solution and (co)polymerization of ethylene uses two different types of catalysts in the two reactors. A catalyst having a phosphinimine ligand is used in the first reactor. A Ziegler Natta catalyst is used in the second reactor. The process of this invention is comparatively easy to control and may be used to produce polyethylene products having a broad molecular weight distribution. Linear low density produced according to this invention is well suited for the manufacture of molded goods and plastic films. | 2 |
FIELD OF THE INVENTION
The present invention generally relates to electronic ballast of fluorescent lamps, and more specifically to a power factor correction circuit for the electronic ballast of the fluorescent lamp.
BACKGROUND OF THE INVENTION
Electronic ballasts, due to its small form factor, light weight, less power consumption, and stable light beams, have become the mainstream of fluorescent lamp ballast. Basically the electronic ballast is a combination of circuits that converts alternating current (AC) into direct current (DC) and then from DC back to AC. More specifically, one of the conventional electronic ballasts converts the AC voltage from the mains into a DC voltage, and then converts the DC voltage, through high frequency oscillation, into a high frequency, high level AC voltage to excite the fluorescent lamp. As shown in FIG. 1 , the conventional electronic ballast contains a bridge rectifier circuit 10 , a DC filter circuit 12 , a high frequency oscillation circuit 14 , and a lamp circuit 16 . For the sake of simplicity and cost reduction, the DC filter circuit 12 usually only contains a filtering capacitor C 1 .
The bridge rectifier circuit 10 that rectifies an input AC voltage to charge and discharge the filtering capacitor C 1 and a DC voltage with a ripple is thereby developed across the filtering capacitor C 1 . Because the AC voltage Vs can charge the filtering capacitor C 1 only around the crest and trough of its waveform where it has a large enough voltage, the input AC current Is therefore has an impulse waveform. Moreover, in order to reduce the ripple of the DC voltage (i.e. to enhance the filtering effect), usually a capacitor with a large capacitance is used as the filtering capacitor C 1 . This, however. causes the impulse waveform of the input AC current Is to become even acuter.
FIG. 2 is a waveform diagram showing the input AC voltage Vs and current Is of the conventional electronic ballast. As shown in FIG. 2 , the input AC current Is has a seriously distorted impulse waveform. The acute impulses cause an increase in the amount of harmonics (especially the third order harmonics) and a reduction of power factor. The increase of harmonics intensifies electromagnetic interference. If a large number of such electronic ballasts are used simultaneously, there is a high possibility to cause a tripping of the power supply system or even a fire accident in the worst case. On the other hand, a reduction of power factor would increase the power consumption of the power supply system and therefore the power bill as well.
A reduction in the capacitance of the filtering capacitor C 1 could indeed abate the distortion of the input AC current Is, reduce the amount of harmonics, and improve the power factor. The DC voltage developed across the filtering capacitor C 1 , however, would have a more fluctuant ripple. This in turn causes the crest factor of the current of the lamp tube 17 (the peak value divided by the effective value of the lamp current) to exceed the normal rating and thereby reduce the lifespan of the lamp tube 17 . In summary, for the conventional electronic ballasts, reducing input AC current harmonics/increasing power factor and reducing lamp current crest factor are contradictory to each other.
Most, if not all, of the commercially available electronic ballasts, even though usually branded as “high efficiency,” commonly have a total harmonic distortion ≧10%, power factor ≈0.5, and lamp current crest factor ≧1.7. In other words, these so-called “high efficient” electronic ballasts actually have a high amount of harmonics and a rather low power factor. The term “high efficiency,” therefore, actually refers to the high frequency lamp lighting. To achieve the true high efficiency, a correction circuit must be added in the electronic ballasts to overcome the foregoing limitations and disadvantages of the conventional electronic ballasts.
Currently, to reduce the amount of harmonics of the input AC current and to increase the power factor at the same time, there are generally two types of correction circuits: the active ones and the passive ones. The active power factor correction circuits adopt active elements and therefore have a complex structure, bulky form factor, and a higher cost. The passive power factor correction circuits can only achieve limited improvement and therefore have little value in real-life applications.
SUMMARY OF THE INVENTION
The present invention provides a power factor correction circuit, which comprises a plurality of diodes and capacitors and is located between a bridge rectifier circuit and a high frequency oscillation circuit to replace a single-capacitor DC filter circuit of the conventional electronic ballast. The power factor correction circuit according to the present invention comprises a filtering capacitor charge/discharge circuit and a feedback circuit taking input from a lamp filament. The former offers a smaller equivalent filtering capacitance so that the input AC current has a smoother waveform and thereby a less amount of harmonics is achieved. The former also offers a larger equivalent capacitance so that the RC time constant is increased when discharging to the load. This in turn reduces the ripple fluctuation and therefore the crest factor of the lamp current. On the other hand, the latter further adds the high frequency voltage feedback from the lamp filament onto the low frequency DC voltage output from the bridge rectifier circuit so that the waveform of the input AC current can further approach true sine wave.
The power factor correction circuit provided by the present invention achieves simultaneously a low amount of input AC current harmonics (the total harmonic distortion <10%), a high power factor (the power factor >0.95), and a less-than-rating lamp current crest factor (the lamp current crest factor <1.7). The provided power factor correction circuit also has advantages, such as small form factor, low cost, and high working reliability. The power factor correction circuit according to the present invention is especially suitable for application in self-excited electronic ballasts with small to medium power consumption.
The foregoing and other objects, features, aspects and advantages of the present invention will become better understood from a careful reading of a detailed description provided herein below with appropriate reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a circuit diagram of a conventional electronic ballast.
FIG. 2 is a waveform diagram showing an input AC voltage Vs and current Is of the conventional electronic ballast.
FIG. 3 is a circuit diagram of an electronic ballast according to a preferred embodiment of the present invention.
FIG. 4 is a waveform diagram showing an input AC voltage Vs and current Is of the electronic ballast of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
A power factor correction circuit provided by the present invention is structured on and works along with a conventional electronic ballast circuit. A preferred embodiment of the power factor correction circuit in accordance with the present invention is described in details as follows.
FIG. 3 is a circuit diagram of the electronic ballast according to the preferred embodiment of the present invention. As shown in FIG. 3 , a bridge rectifier circuit 10 , a high frequency oscillation circuit 14 , and a lamp circuit 16 of the electronic ballast of the present invention are generally identical to the counterparts employed in a conventional electronic ballast and thus, some details may be neglected for simplifying the present description.
The power factor correction circuit provided by the present invention comprises a filtering capacitor charge/discharge circuit and a feedback circuit. Details about the filtering capacitor charge/discharge circuit are explained first as follows.
Diodes D 1 –D 5 and capacitors C 1 and C 2 constitute the filtering capacitor charge/discharge circuit. A positive output terminal of the bridge rectifier circuit 10 connects to anode of a diode D 5 . Between a point B at cathode of diode D 5 and a point C at a negative output terminal of the bridge rectifier circuit 10 , a filtering capacitor C 1 and a diode D 4 are arranged in a series connection. Anode of the diode D 4 is connected to the point C. Also arranged between the points B and C in a series connection are a diode D 3 and a filtering capacitor C 2 that are parallel to the C 1 and D 4 connection. Cathode of the diode D 3 is connected to the point B. The interconnection point between the filtering capacitor C 1 and diode D 4 connects to the interconnection point between the diode D 3 and filtering capacitor C 2 via series-connected diodes D 1 and D 2 . Cathode of the diode D 4 is connected to anode of the diode D 1 . Cathode of the diode D 2 is connected to anode of the diode D 3 .
In the filtering capacitor charge/discharge circuit, the current charging the filtering capacitors C 1 and C 2 flows from the point B to the point C through the filtering capacitor C 1 , diodes D 1 and D 2 , and the filtering capacitor C 2 . On the other hand, the current discharged from the filtering capacitor C 1 flows through the point B, the load, the point C, the diode D 4 , and then back to the filtering capacitor C 1 . Similarly, the current discharged from the filtering capacitor C 2 flows through the diode D 3 , the point B, the load, the point C, and then back to the filtering capacitor C 2 .
From the point B, the DC voltage output from the bridge rectifier circuit 10 and the diode D 5 , on one hand, drives the high frequency oscillation circuit 14 and, on the other hand, charges the filtering capacitor C 1 and C 2 through the afore-mentioned charging path. In the charging path, the filtering capacitors C 1 and C 2 actually form a series connection. Assuming the diodes D 1 and D 2 are ideal (that is, ignoring their conductive resistances) and the capacitances of the filtering capacitors C 1 and C 2 are both C, the equivalent filtering capacitance equals to (C×C)/(C+C)=C/ 2 when the filtering capacitors C 1 and C 2 are charged. That is, the equivalent filtering capacitance when both filtering capacitor C 1 and C 2 are used is 50% less than when a single filtering capacitor C 1 or C 2 is used. Due to this reduction of equivalent filtering capacitance, the input AC current Is has a smoother waveform, fewer amounts of harmonics, and higher power factor.
When the DC voltage at the point B is less than the sum of the voltages of the filtering capacitors C 1 and C 2 , the filtering capacitors C 1 and C 2 discharge to the load in parallel. Assuming the diodes D 1 and D 2 are ideal (that is, ignoring their conductive resistance) and the capacitances of the filtering capacitors C 1 and C 2 are both C, the equivalent filtering capacitance equals to (C+C)=2C when the filtering capacitors C 1 and C 2 discharge. That is, the equivalent filtering capacitance when both filtering capacitor C 1 and C 2 are used is 100% more than when a single filtering capacitor C 1 or C 2 is used. The RC time constant when the filtering capacitors C 1 and C 2 discharge therefore is 100% more than when a single filtering capacitor C 1 or C 2 is used. Due to this increase of equivalent filtering capacitance, the DC voltage and the current of the lamp tube 17 would be less fluctuant and the lamp current would have a lower crest factor.
The details of the feedback circuit will be described as follows. As shown in FIG. 1 , within the conventional lamp circuit 16 , a filament terminal of the lamp tube 17 is connected to an output of the high frequency oscillation circuit 14 via a coupling capacitor C 6 . Within the preferred embodiment of the present invention, as shown in FIG. 3 , a filament terminal of the lamp tube 17 is connected via the coupling capacitor C 6 to the point A between the diodes D 1 and D 2 of the filtering capacitor charge/discharge circuit. The point A, on one hand, connects to the point C via a capacitor C 3 and, on the other hand, connects to the point B via a series-connected capacitor C 4 and diode D 6 . Cathode of the diode D 6 is connected to the point B.
The high frequency signal at the filament terminal of the lamp tube 17 reaches the point A via the coupling capacitor C 6 . The positive halves of the periods of the high frequency signal charge the filtering capacitor C 2 via the diode D 2 and the negative halves of the periods of the high frequency signal charge the filtering capacitor C 1 via the diode D 1 . Moreover, the high frequency signal is rectified by the diode D 6 and added to the low-frequency DC voltage at the point B. The filtering capacitor charge/discharge circuit then filters the sum of the two voltages. The addition of the high frequency signal makes the waveform of the input AC current Is smoother and closer to the sine wave. This in turn further reduces the ripple of the DC voltage and therefore the crest factor of the current of the lamp tube 17 as well.
FIG. 4 is a waveform diagram showing an input AC voltage Vs and current Is of the electronic ballast according to the preferred embodiment of the present invention. As shown in FIG. 4 , because of the power factor correction circuit of the present invention, the input AC current Is has a waveform very close to a true sine wave. Compared with the acute impulse waveform of the conventional electronic ballast as shown in FIG. 2 , it is obvious that a significant improvement is achieved.
The highly efficient power factor correction circuit provided by the present invention has the following advantages:
(1) The amount of the third order harmonics of the input AC current is reduced. The total harmonic distortion is reduced to below 10%. Therefore the electromagnetic pollution is reduced and the power safety is increased.
(2) The power factor is increased to above 0.95. The overhead of the power supply system is therefore reduced.
(3) The fluctuation of the DC voltage is reduced. The crest factor of the lamp tube's lamp current is reduced to below 1.7. The lifespan of the lamp tube is therefore increased. The reliability of the high frequency oscillation circuit is increased. The overall reliability of the whole electronic ballast is therefore increased as well. | A power factor correction circuit for the electronic ballast of a fluorescent lamp is provided. The power factor correction circuit is located between a bridge rectifier circuit and A high frequency oscillation circuit of the electronic ballast, and includes a filtering capacitor charge/discharge circuit and a feedback circuit taking input from a filament of the fluorescent lamp. The electronic ballast equipped with the power factor correction circuit achieves a power factor >0.95, a lamp current crest factor <1.7, and a total harmonic distortion <10%. | 8 |
This application claims the benefit of the Korean Patent Application No. 10-2003-0101395, filed on Dec. 31, 2003, which is hereby incorporated by reference as if fully set forth herein.
BACKGROUND OF THE INVENTION
Field of the Invention
The present invention relates to a lighting optical system, and more particularly, to a small-sized lighting optical system with an improved performance.
Technical advances in display devices have created lighter, thinner and larger screens.
Examples of such display device include projectors or big-screen projection TVs.
In recent years, micro devices have been introduced as a new technology for projectors and projection TVs. Examples of micro device include backlit LCD (HTPS) panels, reflective LCoS (Liquid Crystal on Silicon) panels, and DMD (Digital Micromirror Device) panels.
Depending on how many micro devices are used, the projectors or the projection systems can be categorized as single-panel, double-panel, and triple-panel projectors or projection systems.
In case of the backlit LCD (HTPS), triple-panel optical systems are widely used. As for the LCoS triple-panel, double-panel and single-panel optical systems are all available. As for the DMD, single-panel optical systems are generally used. However, it should be noticed that each of these examples does not always have advantages only.
For instance, a triple-panel optical system for the backlit LCD (HTPS) has too many optical elements and includes a relay lens for compensating optical path differences.
Besides the relay lens, the backlit LCD uses an X-prism for combining colors.
Since there is an optical path difference among R, G and B lights, there was a need to develop a new optical system capable of compensating the optical path difference. That was how the X-prism got involved therein.
FIG. 1 is a schematic diagram illustrating a triple-panel projection system according to a related art.
Referring to FIG. 1 , the triple-panel projection system includes a lamp 110 for emitting light; fly-eye lenses 120 , 121 for splitting the light emitted from the lamp 110 into micro lens cell units; a PBS (Polarizing Beam Array) 130 for forming incident light into a linearly polarized light with one optical axis; condensing lenses 140 , 142 , 142 for condensing light; dichroic lenses 151 , 152 for splitting the light into R, G and B colors; LCDs (Liquid Crystal Displays) 161 , 162 , 163 for providing or displaying R, G and B images; mirrors 171 , 172 , 173 for changing a traveling path of each of the split lights by the dichroic lenses 151 , 152 so that the split lights travel to their corresponding LCDs 161 , 162 , 163 , respectively; relay lenses 181 , 182 disposed on the traveling path of light to focus the light to a desired position; and an X-prism 190 for combining images from the LCDs 161 , 162 , 163 , respectively.
The following will now explain the operation of the related art projection system described above.
The light from the lamp 110 incidents on the first dichroic lens 151 .
The first dichroic lens 151 then reflects red light and transmits cyan light.
The red light reflected from the first dichroic lens 151 is reflected again by the mirror 171 and incidents on the first LCD 161 .
The second dichroic lens 152 reflects green light and transmits blue light.
The green light reflected from the second dichroic lens 152 incidents on the second LCD 162 .
The blue light transmitted through the second dichroic lens 152 goes through the relay system 200 consisting of the first and second relay lenses 181 , 182 , and the first and second mirrors 172 , 173 , and as a result the light path difference of the blue light from the red and green lights is compensated. Afterwards the blue light incidents on the third LCD 163 .
The incident lights on the first, second and third LCDs 161 , 162 , 163 experience phase modulation according to an input signal and put corresponding image information therein. The lights containing the image information are then emitted from the first, second and third LCDs 161 , 162 , 163 , are synthesized through the X-prism 190 , and reach a screen (not shown) by means of a projection lens (not shown).
The above-described projection system (or projector) requires a number of optical elements for splitting and combining colors.
It also requires the relay system for compensating the light path of the blue light to make it equal to those of the red and green lights.
Because of the relay system the size of a light engine is increased, more optical elements are required, and a great number of elements should be adjusted to array an optical axis.
Meanwhile, the red and blue lights were in the same polarization state to obtain a maximum light efficiency taking advantage of the X-prism, but the green light had a different polarization state. Therefore, a retardation plate was additionally installed next to the X-prism to make the green light have the same polarization state with that of the red and blue lights.
SUMMARY OF THE INVENTION
Accordingly, the present invention is directed to a lighting optical system that substantially obviates one or more problems due to limitations and disadvantages of the related art.
An object of the present invention is to provide an lighting optical system having less elements and a simple constitution.
Another object of the present invention is to provide a lighting optical system without a relay system by fixing the distances from R, G and B LCDs to a projection lens.
Still another object of the present invention is to provide a lighting optical system with an improved performance by conforming the polarization states of output lights.
Additional advantages, objects, and features of the invention will be set forth in part in the description which follows and in part will become apparent to those having ordinary skill in the art upon examination of the following or may be learned from practice of the invention. The objectives and other advantages of the invention may be realized and attained by the structure particularly pointed out in the written description and claims hereof as well as the appended drawings.
To achieve these objects and other advantages and in accordance with the purpose of the invention, as embodied and broadly described herein, a lighting optical system, comprising, a light separating means for separating incident light into three colored lights according to wavelength bands, and progressing the three separate colored lights for the same amount of distance from a light source of the incident light through different optical paths, and emitting the three separate colored lights to a first, a second and a third LCD, a first, a second and a third LCD for respectively receiving the three colored lights from the light separating means, and forming images therefrom; and a light combining means for synthesizing the three colored lights emitted from the first, second and third LCD, and outputting the synthesized light outside.
Preferably, the light separating means includes a first and a second color separating plane inclinedly disposed in parallel with the direction of the incident light, and a total reflection plane disposed in parallel with a direction perpendicular to the first color separating plane and the incident light.
In the exemplary embodiment of the present invention, the light separating means includes a group of prisms, the prisms reflecting through the first color separating plane light in the first wavelength band towards the total reflection plane at right angles to the incident light; reflecting through the second color separating plane light in the second wavelength band and emitting the light outside in a direction perpendicular to the incident light; reflecting through the total reflection plane the light in the first wavelength band from the first color separating plane and emitting the light outside in parallel with the incident light; and emitting light in the third wavelength band outside provided that the light transmits through the first and second color separating planes.
Preferably, the light separating means includes: a first parallelogram-shaped prism with one inclined surface being formed of a first color separating plane and the other inclined surface being formed of a total reflection plane; a second parallelogram-shaped prism with a second color separating plane formed on one inclined surface; and a triangle-shaped prism.
Preferably, the first parallelogram-shaped prism is installed in such a manner that the first color separating plane receives the incident light through the one inclined surface, and the total reflection plane is disposed in parallel to a direction perpendicular to the first color separating plane; the second parallelogram-shaped prism is installed in such a manner that the second color separating plane is in parallel with the first color separating plane of the first parallelogram-shaped prism, and an inclined surface on which the second color separating surface is not formed is tightly attached to the first color separating plane of the first parallelogram-shaped prism and is not exposed to air; and the triangle-shaped prism is installed in such a manner that an inclined surface thereof is tightly attached to the second color separating surface of the second parallelogram-shaped prism and is not exposed to air.
Preferably, the light separating means includes a first triangle-shaped prism having a first color separating plane formed on one inclined surface, a second triangle-shaped prism having a second color separating plane formed on one inclined surface, a third triangle-shaped prism having a total reflection plane formed on one inclined surface, and two triangle-shaped prisms.
Preferably, the first and second color separating planes on the first and second triangle-shaped prisms are disposed, respectively, in parallel with in a direction of the incident light, and the total reflection plane of the third triangle-shaped prism is disposed in parallel with a direction perpendicular to the first color separating plane of the first triangle-shaped prism.
Preferably, the light separating means includes a plurality of triangle-shaped prisms or a plurality of parallelogram-shaped and triangle-shaped prisms.
Preferably, the light combining means includes a first and a second color combining plane inclinedly disposed in parallel with the direction of the incident light, and a total reflection plane disposed in parallel with a direction perpendicular to the first color separating plane and the incident light.
Preferably, the light combining means includes a group of prisms, in which the prisms synthesizes, through the first color combining plane, an emitted light from the first LCD with an emitted light from the second LCD, transmitting an emitted light from the first LCD, and synthesizing the emitted light from the second LCD with the emitted light from the first LCD and reflecting the synthesized light; reflects, through the total reflection plane, the emitted light from the third LCD, in a direction at right angles to the incident light and outputting the same to the second color combining plane; and synthesizes, through the second color combining plane, the emitted light from the first color combining plane with the emitted light from the total reflection plane, and emitting the synthesized light outside.
Preferably, the second color combining plane reflects the emitted light from the first color combining plane in a direction at right angles to the incident light, synthesizes the same with the emitted light from the total reflection plane, and emits the synthesized light outside.
Preferably, the second color combining plane reflects the emitted light from the total reflection plane in a traveling direction of the incident fight, synthesizes the same with the emitted light from the first color combining plane, and emits the synthesized light outside.
Preferably, the light combining means includes: a first triangle-shaped prism having the first color combining plane formed on one inclined surface; a second triangle-shaped prism having the second color combining plane formed on one inclined surface; a parallelogram-shaped prism having the total reflection plane formed on one inclined surface; and a third triangle-shaped prism having one inclined surface attached to the first color combining plane between the first triangle-shaped prism and the first LCD.
Preferably, the light combining means includes: a first triangle-shaped prism having the first color combining plane formed on one inclined surface; a parallelogram-shaped prism, having the second color combining plane formed on one inclined surface and the total reflection plane formed on another inclined surface that is in parallel with the afore-said inclined surface; a second triangle-shaped prism having the second color combining plane formed on one inclined surface; and a third triangle-shaped prism having one inclined surface attached to the first color combining plane between the first triangle-shaped prism and the first LCD.
Preferably, the light combining means includes: a first triangle-shaped prism having the first color combining plane formed on one inclined surface; a second triangle-shaped prism having the second color combining plane formed on one inclined surface; a third triangle-shaped prism having the total reflection plane formed on one inclined surface; a fourth triangle-shaped prism having an inclined surface attached to the second color combining plane between the second triangle-shaped prism and the third triangle-shaped prism; and a fifth triangle-shaped prism having one inclined surface attached to the first color combining plane between the first triangle-shaped prism and the first LCD.
Preferably, the light combining means includes: a first triangle-shaped prism having the first color combining plane formed on one inclined surface; a second triangle-shaped prism having the second color combining plane formed on one inclined surface; a third triangle-shaped prism having the total reflection plane formed on one inclined surface; a fourth triangle-shaped prism having an inclined surface attached to the second color combining plane between the first triangle-shaped prism and the second triangle-shaped prism; and a fifth triangle-shaped prism having one inclined surface attached to the first color combining plane between the first triangle-shaped prism and the first LCD.
Preferably, the light combining means includes: a first parallelogram-shaped prism, having the second color combining plane formed on one inclined surface and the second color combining plane formed on another inclined surface; a second parallelogram-shaped prism having the total reflection plane formed on another inclined surface; and a triangle-shaped prism having one inclined surface attached to the first color combining plane between the first triangle-shaped prism and the first LCD.
Preferably, the light combining means includes: a first parallelogram-shaped prism having the first color combining plane formed on one inclined surface; a second parallelogram-shaped prism, having the second color combining plane formed on one inclined surface and the total reflection plane formed on another inclined surface; and a triangle-shaped prism having one inclined surface attached to the first color combining plane between the first triangle-shaped prism and the first LCD.
Preferably, the light combining means includes a plurality of triangle-shaped prisms, or at least one parallelogram-shaped prism and at least one triangle-shaped prism are tightly attached in such a manner that from a plane of incidence on which the three colored lights emitted from the LCDs to a plane of emission from which a synthesized light with the three colored lights is emitted are not exposed to air.
Preferably, the lighting optical system according to the present invention includes in front of the light separating means: a lamp for emitting non-polarized white light; eye-fly lenses for splitting the white light emitted from the lamp into micro lens cell units; and a PBS array for transforming the non-polarized white light into the polarized white light.
It is to be understood that both the foregoing general description and the following detailed description of the present invention are exemplary and explanatory and are intended to provide further explanation of the invention as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this application, illustrate embodiment(s) of the invention and together with the description serve to explain the principle of the invention. In the drawings:
FIG. 1 is a schematic diagram of a triple-panel projection system according to a related art;
FIG. 2 illustrates a triple-panel lighting optical system according to a first embodiment of the present invention;
FIG. 3 illustrates a triple-panel lighting optical system according to a second embodiment of the present invention;
FIG. 4 illustrates a triple-panel lighting optical system according to a third embodiment of the present invention;
FIG. 5 illustrates a triple-panel lighting optical system according to a fourth embodiment of the present invention;
FIG. 6 illustrates a triple-panel lighting optical system according to a fifth embodiment of the present invention;
FIG. 7 illustrates a triple-panel lighting optical system according to a sixth embodiment of the present invention; and
FIG. 8 is a diagram to explain traveling distances of three color lights from a color separating prism to first, second and third LCDs, respectively, in a triple-panel lighting optical system according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings.
FIG. 2 illustrates a triple-panel lighting optical system according to a first embodiment of the present invention.
As shown in FIG. 1 the lighting optical system includes a lamp 210 , a polarization converting system 220 , a color-separating prism group 230 (a first, a second and a third dichroic prism 231 , 232 , 233 ), a first, a second and a third LCD 240 , 250 , 260 , and a color combining prism group 270 (a first, a second, a third and a fourth color combining prism 271 , 272 a , 272 b , 273 .
The polarization converting system 22 —includes a first and a second fly-eye lens 220 a , 220 b , and a PBS array 220 c.
The first and second fly-eye lenses 220 a , 220 b split white light emitted from the lamp 210 into micro lens cell units, thereby resulting in a uniform light distribution.
The PBS array 220 c separates an incident light to linearly polarized light having one optical axis, namely p-polarization and s-polarization. Here, the PBS array 220 c emits an S-wave as it is, but converts a P-wave to an S-wave by means of a ½ wave plate (not shown) before emitting. In this manner, the resulting polarization states are conformed.
The color separating prism 230 separates a polarized light inputted through the polarization converting system 220 into red, green and blue lights, and output the lights to different paths from each other.
To this end, the color separating prism group 230 has an approximately ‘L’ shape.
The color separating prism group 230 includes the first and second color separating prisms 231 , 232 in the parallelogram shape, and the third color separating prism 233 in the triangle shape.
The first color separating prism 231 forms a first dichroic coating 230 b on one inclined surfaces, and a total reflection coating 230 c on the other inclined surface.
The second color separating prism 232 forms a second dichroic coating 230 b on one inclined surface.
Here, the first dichroic coating 230 a and the second dichroic coating 230 b are disposed in parallel with the X-axis direction. And the first dichroic coating 230 a and the total reflection coating 230 c are disposed in parallel with the Y-axis direction.
The inclined surface of the third color separating prism 233 is attached to the second dichroic coating 230 b of the second color separating prism 232 in such a manner that the first, second and third color separating prisms 231 , 232 , 233 are not exposed to air.
The first and second dichroic coatings 230 a, 230 b and the total reflection coating 230 c are disposed in angles so that the emission direction of the light reflected therefrom is at right angles to the direction of incidence.
Therefore, the light reflected from the first and second dichroic coatings 230 a , 230 b is emitted in the Y-axis direction that makes a right angle with the X-axis direction.
The light, which was reflected from the first dichroic coating 230 a and traveled along the Y-axis direction, is then reflected by the total reflection coating 230 c and travels in the X-axis direction.
More specifically speaking, the first dichroic coating 230 a reflects a desired wavelength band, the red light for example, towards the total reflection coating 230 c, and transmits the cyan (G, B) light towards the second dichroic coating 230 b.
The total reflection coating 230 c reflects again the red light that has been reflected from the first dichroic coating 230 a, and emits it outside through a first plane of emission S 1 .
The second dichroic coating 230 b reflects the green light for example out of the transmitted cyan light, and emits it outside through a second plane of emission S 2 . The residual blue light is emitted outside through a third plane of emission S 3 .
The first, second and third LCDs 240 , 250 , 260 are disposed, respectively, on the light paths of RGB lights corresponding to the first through third planes of emission S 1 , S 2 , S 3 . In other words, when RGB lights are emitted from the first, second and third planes of emission S 1 , S 2 , S 3 , the first, second and third LCDs 240 , 250 , 260 installed on opposite sides of those planes provide RGB images, respectively.
The color separating prism group 230 is designed in such a manner that the traveling distance of each of the RGB lights from the lamp (the light source) 210 to the first, second and third LCDs 240 , 250 , 260 is the same (please refer to FIG. 8 ).
In other words, the distances from the plane of incidence of the color separating prism group 230 to the first LCD 240 (A 1 +A 2 ), the second LCD 250 (B 1 +B 2 ) and the third LCD 260 (C 1 +C 2 ) are all the same.
Since the traveling distances of the incident light from the lamp 210 to the first, second and third LCDs 240 , 250 , 260 via the color separating prism 230 are the same, a relay system is no longer needed.
The color combining prism group 270 combines RGB lights emitted from the first, second and third LCDs 240 , 250 , 260 , and outputs white light (R+G+B) to outside.
The color combining prism group 270 is similar to the 180 degree-rotated color separating prism group.
The color combining prism group 270 includes a first color combining prism 271 in the parallelogram shape, and a second, a third and a fourth color combining prism 272 a , 272 b , 272 in the triangle shape, each of the color combining prisms being made out of the same material.
Here, an inclined surface of the second color combining prism 272 a forms a third dichroic coating 270 a.
Similarly, an inclined surface of the second color combining prism 272 b forms a fourth dichroic coating 270 b.
Also, a total reflection coating 270 c is formed on one inclined surface of the first color combining prism 271 in the parallelogram shape.
The third dichroic coating 270 a and the fourth dichroic coating 270 b are disposed in parallel with the X-axis direction. The fourth dichroic coating 270 b and the total reflection coating 270 c are disposed in parallel with the Y-axis direction. Later the parallelogram-shaped prism 271 and the three triangle-shaped prisms 272 a , 272 b , 273 are attached to each other not to be exposed to air.
The fourth color combining prism 273 is attached in such a manner that it is not exposed to air especially between the second color combining prism 272 a and the first LCD 240 .
The third dichroic coating 270 a transmits a light element, the red light for example, entering through the first plane of incidence T 1 , and reflects in the X-axis direction a light element, the green light for example, entering through a second plane of incidence T 1 , whereby a yellow light synthesized with the red and green lights is outputted towards the fourth dichroic coating 270 b.
The total reflection coating 270 c reflects a light element, the blue light for example, which enters through the third plane of incidence T 3 , in the direction of the fourth dichroic coating 270 b.
The fourth dichroic coating 270 b transmits the blue light from the total reflection coating 270 c and reflects the yellow light (R,G) from the third dichroic coating 270 a , whereby a white light synthesized with the blue and yellow lights is outputted to outside.
FIG. 3 illustrates a triple-panel lighting optical system according to a second embodiment of the present invention.
The constitution of the triple-panel lighting optical system according to the second embodiment of the present invention is basically similar to that of the first embodiment of the present invention, except for one difference in the following.
The fourth dichroic coating 270 b is not formed on the inclined surface of the third color combining prism 272 b , but on the inclined surface of the first color combining prism 271 that is in parallel with the total reflection coating 270 c. As a result, the yellow light from the third dichroic coating 270 a is transmitted through the second color combining prism 272 b , and the blue light from the total reflection coating 270 a is reflected in the X-axis direction by the fourth dichroic coating 270 b. More specifically, the synthesized light with yellow and blue is outputted outside along the X-axis.
Since the rest of constitution and functions are identical with those of the first embodiment, they will not be discussed here.
FIG. 4 illustrates a triple-panel lighting optical system according to a third embodiment of the present invention.
The triple-panel lighting optical system according to the third embodiment of the present invention includes a color separating prism group 230 consisting of five triangle-shaped prisms, and a color combining prism group 270 consisting of five triangle-shaped prism.
To make the color separating prism group 230 , five triangle-shaped prisms made out of the same material are prepared. First and second dichroic coatings 230 a, 230 b are formed on the inclined surfaces of two triangle-shaped prisms 231 b , 232 b , respectively, and a total reflection coating 230 c is formed on the inclined surface of another triangle-shaped prism 231 a . These five triangle-shaped prisms are then attached to each other in such a manner that the first and second dichroic coatings 230 a, 230 b are disposed in parallel with the X-axis direction, and the first dichroic coating 230 a and the total reflection coating 230 c are disposed in parallel with the Y-axis direction.
In like manner, five triangle-shaped prisms (a first to a fifth color combining prism) 271 a , 271 b , 272 a , 272 b , 273 made out of the same material are prepared to make the color combining prism 270 . Then third and fourth dichroic coatings 270 a , 270 b are formed on the inclined surfaces of the third and the fourth color combining prisms 272 a , 272 b , respectively, and a total reflection coating 270 c is formed on the inclined surface of the second color combining prism 272 b . These five triangle-shaped prisms are attached to each other in such a manner that the third and fourth dichroic coatings 270 a , 270 b are disposed in parallel with the X-axis direction, and the third dichroic coating 270 a and the total reflection coating 270 c are disposed in parallel with the Y-axis direction.
The fourth dichroic coating 270 b transmits the blue light from the total reflection coating 270 c , and reflects in the Y-axis direction the yellow light (R,G) from the third dichroic coating 270 a , whereby a white light synthesized with the blue and yellow lights is outputted outside along the Y-axis direction.
FIG. 5 illustrates a triple-panel lighting optical system according to a fourth embodiment of the present invention.
The constitution of the triple-panel lighting optical system according to the fourth embodiment of the present invention is basically similar to that of the third embodiment of the present invention, except for one difference in the following.
The fourth dichroic coating 270 b in the fourth embodiment is formed on an inclined surface of the first color combining prism 271 a. In other words, unlike in the third embodiment of the present invention, the fourth dichroic coating 270 b transmits in the X-axis direction the yellow light from the third dichroic coating 270 a , and also reflects in the X-axis direction the blue light from the total reflection coating 270 c. As a result, a white light synthesized with the blue and yellow lights is outputted outside along the X-axis direction.
FIG. 6 illustrates a triple-panel lighting optical system according to a fifth embodiment of the present invention.
The constitution of the triple-panel lighting optical system according to the fifth embodiment of the present invention is basically similar to that of the first embodiment of the present invention, except for one difference in the following.
Instead of using two triangle-shaped color combining prisms 272 a , 272 b as illustrated in FIG. 2 , in the fifth embodiment of the present invention a parallelogram-shaped color combining prism 272 (a second color combining prism) is employed. The third dichroic coating 270 a is formed on one inclined surface of the second color combining prism 272 , and the fourth dichroic coating 270 b is formed on another inclined surface of the second color combining prism 272 .
Since the rest of constitution and functions are identical with those of the first embodiment, they will not be discussed here.
FIG. 7 illustrates a triple-panel lighting optical system according to a sixth embodiment of the present invention.
The constitution of the triple-panel lighting optical system according to the sixth embodiment of the present invention is basically similar to that of the second embodiment of the present invention shown in FIG. 3 , except for one difference in the following.
Instead of using two triangle-shaped color combining prisms 272 a , 272 b as illustrated in FIG. 3 , in the sixth embodiment of the present invention a parallelogram-shaped color combining prism 272 (a second color combining prism) is employed. The third dichroic coating 270 a is formed on one inclined surface of the second color combining prism 272 , and the fourth dichroic coating 270 b is formed on one of inclined surfaces of the first color combining prism 271 in parallel with the total reflection coating 270 c.
In other words, unlike in the fifth (second?) embodiment of the present invention, the fourth dichroic coating 270 b transmits in the X-axis direction the yellow light from the third dichroic coating 270 a , and also reflects in the X-axis direction the blue light from the total reflection coating 270 c. As a result, a white light synthesized with the blue and yellow lights is outputted outside along the X-axis direction.
Since the rest of constitution and functions are identical with those of the first embodiment, they will not be discussed here.
FIG. 8 is a diagram to explain traveling distances of three color lights from a color separating prism to first, second and third LCDs, respectively, in a triple-panel lighting optical system according to the present invention.
Basically the color separating prism group 230 is designed in such a manner that RGB lights entering the first, second and third LCDs 240 , 250 , 260 through the color separating prism group 230 travel the same amount of distance from the lamp (the light source) 120 .
In other words, the distances from the plane of incidence of the color separating prism group 230 to the first LCD 240 (A 1 +A 2 ), the second LCD 250 (B 1 +B 2 ) and the third LCD 260 (C 1 +C 2 ) are all the same.
Since the traveling distances of the incident light from the lamp 210 to the first, second and third LCDs 240 , 250 , 260 via the color separating prism 230 are the same, a relay system is no longer needed.
Although not illustrated in the drawing, white light outputted from the color combining prism 270 is projected onto the screen through a projection lens and displaced as an image.
In conclusion, the lighting optical system of the present invention has the following advantages.
First, unlike in the related art, the traveling distance of each of the RGB lights from the LCDs to the projection lens are the same so the relay system is not required. This spontaneously fixes problems(such as an increase in the optical engine size, an increase in the optical elements, and a necessity for an optical axis array) that are often caused by installing the relay system in the optical system.
Second, the lighting optical system of the present invention has such a simple constitution that it includes prisms having dichroic coatings and/or total a reflection coating and LCDs only.
Third, instead of the X-prism as in the related art, the present invention utilizes dichroic coatings to synthesize light. This makes it possible to conform the states of polarization of incident lights and emitted lights according to color, and the contrast of the optical system can be corrected more easily.
Fourth, the lighting optical system of the present invention is smaller and cost-effective, and provides superior optical performance.
Fifth, the color separating prisms and the color combining prisms are tightly attached so that none of them is exposed to air, whereby any transformation of the light caused by air during the color separation/combination can be minimized.
The forgoing embodiments are merely exemplary and are not to be construed as limiting the present invention. The present teachings can be readily applied to other types of apparatuses. The description of the present invention is intended to be illustrative, and not to limit the scope of the claims. Many alternatives, modifications, and variations will be apparent to those skilled in the art. | Disclosed is a lighting optical system, including: a ighting optical system, comprising, a light separating means for separating incident light into three colored lights according to wavelength bands, and progressing the three separate colored lights for the same amount of distance from a light source of the incident light through different optical paths, and emitting the three separate colored lights to a first, a second and a third LCD, a first, a second and a third LCD for respectively receiving the three colored lights from the light separating means, and forming images therefrom; and a light combining means for synthesizing the three colored lights emitted from the first, second and third LCD, and outputting the synthesized light outside. | 7 |
BACKGROUND OF THE INVENTION
[0001] The present invention relates generally to weightlifting equipment. More particularly, it relates to an improved exercise apparatus for isolating the triceps muscles.
STATEMENT OF THE PRIOR ART
[0002] Various types of barbell and dumbbell arrangements for isolating specific muscle groups are known. Additionally, other non-traditional exercising apparatus purporting to isolate and exercise a specific muscle group or groups are available. These apparatuses generally suffer from major drawbacks. One major drawback is that all barbell apparatuses having a relatively long bar are difficult to balance. There are two reasons for this difficulty. First, because the bar is long and the weight is very heavy relative to the bar, significant torque is generated since the weights are connected to the end of the bar thus producing a long lever arm depending upon the user hand positions. Also, even most accomplished body builders have strength differences between their left and right arms, requiring the user to exert extra strength to both compensate for the strength difference and balance the weight. Once the user becomes fatigued, the ability to compensate for the weight difference is seriously compromised resulting in a dangerous off balance position which has often resulted in injury.
[0003] Accordingly, some apparatuses which do not use weights have been devised. These apparatuses tend to be associated with large expensive fitness machines which have limited effectiveness for serious body builders and are thus rarely used by them. Furthermore, these apparatuses tend to use mechanical parts which are highly specialized and subject to failure such as rubberized bands and tension means, and hydraulics. Finally, weight bearing exercise apparatuses having a centered weight or weights have been devised. None of these apparatuses is seen to be as effective as the present invention.
[0004] Another common problem with weightlifting equipment, specifically associated with triceps exercisers, is that most equipment used for working triceps require that palms face upward. This type of hand position makes it difficult to keep the elbows inward especially while lifting heavy weight. Without strict form, other upper body muscles are recruited while lifting the weight. This action reduces the effectiveness of the exercise.
[0005] Another common problem with triceps exercisers is the inability to keep proper and strict form while performing overhead triceps extensions. The traditional way to perform this exercise is with either a straight bar or curl bar, in an overhead position, with palms facing up. This exercise requires that the bar be lowered behind the neck and then back up above the head. The problem with this movement is keeping strict form. Due to palm position (facing up) it's awkward keeping elbows in and palms facing up throughout this movement. There's a natural tendency to allow the elbows to protrude outward, away from the body.
[0006] An additional shortcoming germane to free weight assemblies in general, is the need to replace weight plates to increase the effective resistance. While some weight machines allow for repositioning weight plates or weight bearing components in order to increase the effective resistance for a particular exercise, this type of adjustment is not available on barbells, dumbbells, or other free weight supporting apparatuses.
[0007] U.S. Pat. No. 4,605,222 issued to Shannon discloses a weightlifting exercising bar. The bar has a center section with grasping handles formed therein. The weights are disposed on either end of the bar. While this apparatus can be used to isolate triceps, it suffers from the aforementioned balancing problem. The apparatus also allows for only one hand placement. By contrast, the present invention has a centrally located weight plate securing means which substantially reduces the balancing problem.
[0008] U.S. Pat. No. 5,709,634 issued to Pointer discloses a dumbbell adapted to be held behind the user's head while performing sit ups. While Pointer does disclose a central weight, he does not disclose hand position and spacing conducive to triceps extensions. By contrast, the present invention discloses a triceps extension apparatus which allows multiple hand positions and spacing.
[0009] None of the above inventions and patents, taken either singly or in combination, is seen to describe the instant invention as claimed.
SUMMARY OF THE INVENTION
[0010] The present invention overcomes the disadvantages of the prior art by providing a weightlifting apparatus for exercising the triceps. The apparatus includes a central weight bearing section with opposing handles, each handle having multiple gripping positions. The apparatus may be held behind the head and then repeatedly extended over the head in order to isolate and exercise the triceps. The weight bearing section can accommodate a number of weight plates and includes a clamping arrangement for securely holding the plates in a central position. The weight plates are designed to be compact and low profile and are thus of non-standard configuration. At least two plates are provided, the plates designed for interlocking attachment with only a single locking pin. A number of other exercises are facilitated with the apparatus. In an alternative embodiment, means for increasing the effective resistance for specific exercises, while maintaining a given mass, is provided.
[0011] The primary hand position on the apparatus of the present invention requires a closed (facing each other) hand position. By utilizing this unique hand position, the arms are forced to stay closer together, therefore retaining strict triceps isolation throughout the movement. When fatigue sets in during an exercise, there is a tendency to break form to complete the exercise. The apparatus will not allow deviation because the hand position forces the elbows to remain inward.
[0012] Alternatively, the apparatus allows for a standard or traditional hand position. This hand position is achieved by using both hands and grabbing hold of each inside arch of the unit.
[0013] The apparatus alleviates the tendency to resort to improper form, thereby recruiting other muscles to complete the exercise, by changing hand position, by changing from a palms up hand position to an end-to-end hand position. This creates a natural feel, making it easier to keep the elbows perpendicular to the body.
[0014] Accordingly, it is a principal object of the invention to provide an improved weightlifting apparatus for exercising the triceps.
[0015] Accordingly, it is an object of the invention to provide an improved weightlifting apparatus for exercising the triceps which has a centrally located weight bearing section.
[0016] It is another object of the invention to provide an improved weightlifting apparatus for exercising the triceps which has opposing handles with multiple gripping positions.
[0017] It is another object of the invention to provide an improved weightlifting apparatus for exercising the triceps which allow for end to end hand placement.
[0018] It is another object of the invention to provide an improved weightlifting apparatus for exercising the triceps having at least two substantially rectangular, mutually interlocking, low profile weight plates.
[0019] It is another object of the invention to provide an improved weightlifting apparatus for exercising the triceps having means for extending the effective center of gravity of the apparatus to increase resistance for particular exercises.
[0020] Finally, it is a general object of the invention to provide improved elements and arrangements thereof in an apparatus for the purposes described which is inexpensive, dependable and fully effective in accomplishing its intended purposes.
[0021] These and other objects of the present invention will become readily apparent upon further review of the following specification and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] Various other objects, features, and attendant advantages of the present invention will become more fully appreciated as the same becomes better understood when considered in conjunction with the accompanying drawings, in which like reference characters designate the same or similar parts throughout the several views, and wherein:
[0023] FIG. 1 shows a perspective view of the apparatus of the invention.
[0024] FIG. 2 shows a perspective view of the apparatus of the invention with weight plates attached in an extended position.
[0025] FIG. 3 shows a side view of the apparatus of the invention with weight plates attached in an extended position.
[0026] FIG. 4 shows a front view, partly in section, of an alternative embodiment of the weightlifting apparatus of the present invention.
[0027] FIG. 5 shows a front view, partly in section of the weight plates the alternative embodiment of the weightlifting apparatus of the present invention.
[0028] FIG. 6 shows an exploded sectional view of the weight plates of the alternative embodiment of the weightlifting apparatus of the present invention.
[0029] FIG. 7 shows a plan view, partly in section, of the underside of upper weight plate of the weightlifting apparatus shown in FIG. 6
[0030] FIG. 8 shows a top sectional view of the weight plates shown in FIG. 6 detailing the interconnection of the upper and lower plates.
[0031] FIG. 9 shows a side view of a user using the weightlifting apparatus in an initial position.
[0032] FIG. 10 shows a side view of a user using the weightlifting apparatus in a fully extended position.
[0033] FIG. 11 shows a rear view of a user using the weightlifting apparatus in an initial position.
[0034] FIG. 12 shows a side view of a user using the weightlifting apparatus in a fully extended position.
DETAILED DESCRIPTION
[0035] Referring now to FIGS. 1-3 , the apparatus of the present invention, generally indicated by the numeral 1 , is shown. The apparatus 1 , has particular application as a triceps exerciser, its shape facilitating overhead triceps extensions. The apparatus 1 has two main components, the bar and handle assembly, and the support and clamping assembly.
[0036] The bar 10 is preferably formed by bending a single, solid piece of iron bar or tube stock. The tube stock should be about 1 inch in diameter, and should have a total length of about 4 feet. This length of bar 10 will create an optimal hand spacing for the average weightlifter. Of course, the length of the bar 10 may be adjusted to adjust the hand spacing. The surface of bar 10 can be bare metal, plated, plastic coated, or painted, as desired. Also, the surface of the bar 10 may be textured to enhance grip. The bar 10 has two mutually opposed handle extensions, 12 , each extension having a main gripping area 16 , and two alternate gripping areas 18 , 20 . The main handle extension 12 may include a padded sleeve. The final configuration of bar 10 is characterized in that the combined assembly has a center of gravity which lies between handle extensions 12 , both laterally and longitudinally. The center of gravity may be adjusted to increase the effective resistance of the weights as will be explained in connection with the alternative embodiment discussed below. This feature is significant since it enables a user to grasp handles 12 and lift the apparatus 1 without there being a resultant torsional loading exerted on the user's wrists. This feature would not result if the main handle extensions 12 were offset. It can be seen that the bar 10 has a level portion 24 parallel to weight bearing platform 26 which, in the event the bar 10 has a total length of 4 feet long prior to shaping, may be about 4 inches.
[0037] An upstanding post 30 is used to position one or more standard weight plates 32 on the platform 26 , the post 30 secured to the platform by an suitable means, and may even be releasably secured to the platform 26 to allow for the use of smaller diameter posts 30 to accommodate weight plates 32 having various standard center apertures. A key feature of the invention is the provision of a post 30 allowing for positioning weight plates 32 at various distances from the platform 26 to vary the effective resistance for certain exercises as will be explained in more detail below. The weight bearing platform 26 , upstanding post 30 , and releasable clamping means 38 form the support and clamping subassembly. The centrally located weight bearing platform 26 is secured to the bar 10 which may be made of the same material as the bar 10 . Attachment of the platform 26 to the bar 10 is preferably accomplished by welding to eliminate a single stress point, or a plurality of stress points which can cause failure of the apparatus 1 after repeated use or during heavy weightlifting. While the platform 26 is shown as square, any shape will suffice for the platform, provided it is substantially symmetrical. Also, bar 10 may be welded to the underside of the platform 26 allowing the platform 26 to be relatively large. It can be appreciated that the width and length of the platform 26 can be limited to the space 40 between parallel bar segments 42 , 44 and the length of segments 42 , 44 . Of course, the upstanding post 30 is centrally located to ensure that the symmetry of the apparatus 1 is maintained. It can be seen that the post 30 can accommodate a number of weight plates 32 .
[0038] A key aspect of the invention is the provision of a support and clamping assembly which allows one or more weight plates 32 to be suspended above the platform 26 and therefore further away from the hands of the user. It can be appreciated that positioning the weights 32 above the platform creates torsional loading which is directly proportional to the additional length of post 30 between the center of gravity of the plates 32 and the platform 26 . The additional torque, and therefore the effective resistance due to the weight of the plates 32 will be primarily apparent for exercise routines where the arc of motion of the opposed gripping areas 16 of the handle 12 is in the direction shown by arrow 132 . The increased resistance is apparent regardless of which portion of the handle 102 is gripped, provided the motion is perpendicular to post 30 . Any routine such as a bench press where the primary motion is parallel to the bar 10 , as shown with arrow 48 , will not be subject to an increase in resistance other than some additional effort required to balance the apparatus.
[0039] The clamping means 38 consists of a locking collar 52 and spring loaded weight pin 54 , both of which are of standard configuration. The pin 54 is adapted for insertion into and through aligned apertures 56 on opposing sides of post 30 , and preferably at least three discrete positions are available for the insertion of the pin 54 . Once pin 54 is secured through a selected pair of apertures 56 , one or more weight plates 32 may be placed over the post, coming to rest on the pin 54 . Locking collar 52 may then be placed on the post 30 and slid downwardly until coming to rest upon the top surface of the uppermost weight plate 32 . Thus, in use, the user 50 selects a pair of aligned apertures 56 and inserts pin 54 therethrough, adding weight plates 32 and locking collar 52 to secure the apparatus for use. To obtain a different effective weight, the user 50 can select a different pair of apertures 56 .
[0040] An alternative embodiment of the invention is shown in FIGS. 4-8 . A key feature of this embodiment of the invention is the use of mutually interlocking weight plates to allow for a more compact and easily adjustable apparatus 100 . In this configuration, the apparatus 100 is designed for aerobics and muscle toning routines, not for power lifting. While several interlocking weight plates may be used without departing from the spirit of the invention, in the preferred embodiment only two plates are used. It can be seen that the weight plates include an upper plate 128 and a lower plate 130 , the lower plate 130 being secured to the assembly by bolts 132 which are inserted into and through apertures 134 in the weight bearing platform 126 . The platform 126 is secured to the bar 127 by welding as in the previous embodiment, the bar 127 configured in an identical manner to that of the previous embodiment, including multiple gripping areas as discussed above. The apertures 134 correspond to threaded bores 138 formed in lower plate 130 so that bolts 132 extend into and through apertures 134 and are threadedly engaged within bores 138 .
[0041] Weight plates 128 , 130 are configured for interlock by way of downwardly protruding male member 144 extending from upper plate 128 , which is sized for engagement within female receptacle 146 formed in lower plate 130 . It can be seen that laterally opposed edges 147 of the male member 144 are beveled, as are the interior sidewalls 149 of the receptacle 146 to “funnel” the upper plate 128 into position. Bore 148 formed in upper plate 128 is axially aligned with bore 150 formed in lower plate 130 when the male member 144 is properly seated within receptacle 146 . A spring loaded pin 152 , of the type commonly used with barbells, is insertable within the aligned bores, with opposing projecting pieces 154 serving to limit axial movement of the pin 152 as is well known. The upper plate is characterized by a pair of recessed areas 155 which allow easier access to the front edge 157 of the lower plate. Thus, this embodiment allows at least three discrete weight settings, the minimum with no plates, the maximum with at least two plates.
[0042] FIGS. 9-12 illustrate the apparatus 1 being used for a triceps extension exercise. After adding weights as described above, the user 50 assumes an initial or starting position for a particular exercise routine. The initial position of the user 50 when performing the triceps exercise movement is shown with reference to FIGS. 9 and 11 .
[0043] FIG. 9 illustrates a side view of the initial position of the bar with respect to the user. Both hands grasp main gripping areas 16 and the apparatus 1 is placed behind the user's head. The apparatus 1 is thereafter raised along an arc over the user's head to the position shown in FIGS. 10 and 12 . The positioning and orientation of gripping areas 16 is ideal for the triceps extension exercise since the user's hands are positioned end to end. By utilizing this unique hand position, the arms are forced to stay closer together, therefore retaining strict triceps isolation throughout the movement. As the apparatus 1 is lifted over the user's head, there is no resultant torque load being imposed on the user's wrist due to the center of gravity placement described previously. Use of a conventional barbell for this exercise results in an undesirable grasping angle, and the elbows are forced outward, as opposed to the grasping angle illustrated in FIG. 11 where the elbows are in. A more traditional hand placement may be facilitated by grasping the apparatus 1 by grasping either of the alternate gripping areas 18 , 20 . It can be seen that the width of the apparatus 1 also serves a role in causing optimal hand placement as has been previously described. The apparatus may be made slightly larger to accommodate weightlifters with exceptionally wide shoulders. Other exercise routines may be utilized using the apparatuses 1 , 100 , as would be apparent to one of skill in the art.
[0044] From the foregoing description, one skilled in the art can easily ascertain the essential characteristics of this invention and, without departing from the spirit and scope thereof, can make various changes and modifications of the invention to adapt it to various usages and conditions.
[0045] It is to be understood that the present invention is not limited to the sole embodiment described above, but encompasses any and all embodiments within the scope of the following claims: | A weightlifting apparatus for exercising the triceps includes a central weight bearing section with opposing handles, each handle having multiple gripping positions. The combined assembly has a center of gravity which lies between handle extensions 12 , both laterally and longitudinally. The apparatus may be held behind the head and then repeatedly extended over the head in order to isolate and exercise the triceps. The centrally located weight bearing section can accommodate a number of weight plates and includes a clamping arrangement for securely holding the plates in a central position. A number of other exercises are facilitated with the apparatus. | 0 |
BACKGROUND OF THE INVENTION
1. Filed of the Invention
The present invention relates to a bonding head which is used in inner lead bonders, bump transfer bonders, pellet bonders, etc., and more particularly to a tool-holding mechanism for such bonders.
2. Prior Art
In bonders, it is desirable that the entire undersurface of the bonding tool make a uniform contact with the bonding surface of a workpiece upon which the bonding is performed.
One type of conventional bonding tool holder is equipped with an automatic following mechanism that guides the bonding tool to follow the surface configuration of the workpiece. This mechanism is disclosed in, for example, Japanese Patent Application Laid-Open (Kokai) Nos. 63-169730 and 63-169731.
The following mechanisms in these prior art use springs that connect a tool holder, to which a bonding tool is mounted, and a tool attachment which is fastened to the tool-holder of a bonder. Accordingly, when the bonding tool is pressed against the workpiece, the springs bend and the undersurface of the bonding tool conforms to the bonding surface of the workpiece.
In these prior art, the bonding tool is, via springs, pressed against leads of the workpiece which has elasticity. Accordingly, slipping may occur when the tool is pressed against the leads, and there is a deterioration in the bonding precision and bondability.
SUMMARY OF THE INVENTION
Accordingly, the primary object of the present invention is to provide a bonding head that has a tool-holding mechanism which is able to adjust the bonding tool in a short period of time so that the undersurface of the bonding tool is set to be parallel to the surface of the workpiece and which is able to prevent improper pressing contact.
The object of the present invention is accomplished by a unique structure which includes: a central shaft to which a bonding tool is mounted; an oscillating element which is attached to the central shaft; an oscillating element retaining block which retains the oscillating element in a manner that the oscillating element can oscillate; and a retaining means which securely holds the oscillating element in the retaining block by means of vacuum suction adhesion or electromagnets.
With such a structure, if the vacuum suction of the retaining means is switched off (or when the electromagnets of the retaining means are switched off), the oscillating element becomes free to oscillate in any direction in the oscillating element retaining block. As a result, when the undersurface of the bonding tool, which is mounted to the oscillating element via the central shaft, comes into contact with a bonding stage, the undersurface of the bonding tool can conform to the surface of the bonding stage. Under this state, the vacuum suction of the retaining means is switched on (or the electromagnets of the retaining means are switched on), causing the oscillating element to be securely retained in the oscillating element retaining block.
Thus, a parallel alignment of the undersurface of the bonding tool can be accomplished by first causing the bonding tool to contact the bonding stage and then switching on the vacuum or electromagnets. Thus, the operation of obtaining parallel alignment between the bonding tool and workpiece is very easy.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross sectional view illustrating one embodiment of the bonding head assembly according to the present invention;
FIG. 2 is a schematic external view of the embodiment shown in FIG. 1;
FIG. 3 is a cross sectional view which illustrates another embodiment of t invention; and
FIG. 4 is a cross sectional view which illustrates still another embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
One embodiment of the present invention will be described below with reference to FIGS. 1 and 2.
Reference numeral 1 is a retaining block for an oscillating element or oscillating ball 2. The oscillating element 2 is installed on the undersurface of the oscillating element retaining block 1 which is movable up and down by a vertical driving means (not shown). An oscillating element holder 3 is installed on the undersurface of the oscillating element 2. The holder 3 is suspended from the retaining block 1 by means of springs 4.
The oscillating element 2 is a ball having a spherical surface, and indentations 1a and 3a with concave spherical surfaces both having the same radius as the oscillating assembly 2 are formed on the undersurface of the retaining block 1 and the upper surface of the holder 3, respectively. These concave surfaces can snugly contact the convex surface of the oscillating assembly 2. Ring-shaped suction adhesion ports 1b are formed in the spherical-surface indentation la, and suction adhesion holes 1c which open into each of the suction adhesion ports 1b are formed in the retaining block 1. To each of the suction adhesion holes 1c, vacuum suction is applied by a vacuum means (not shown).
Shaft guide holes 1d, 2a and 3b in which a central shaft 5 is inserted are formed on the same vertical axis in the retaining block 1, oscillating assembly 2 and holder 3, respectively. The central shaft 5 is supported in the oscillating assembly 2 via bearings 6 so that the central shaft 5 is rotatable in the guide hole 2a. The top end 5a and the bottom end 5b of the central shaft 5 each passing through the retaining block 1 and holder 3 have a smaller diameter than the corresponding guide holes 1d and 3b. Thus, the central shaft 5 can make a slight inclination in any direction. A bonding tool 7 is attached to the lower end of the central shaft 5.
A spring attachment 10 is fit over the top end 5a of the central shaft 5 so that it is on the upper surface of the retaining block 1. The spring attachment 10 is free to rotate and to move up and down on the central shaft 5. Each of the springs 11 is fastened at one end to the retaining block 1 and at the other end to the spring attachment 10. The central shaft 5 is maintained in a more or less vertical position by these springs 11.
A pulley 12 is attached to the central shaft 5 so that the pulley is positioned above the spring attachment 10. The upper end of the central shaft 5 is fixed with a load cell 13.
A motor 14 that makes a rotary adjustment of the bonding tool is mounted on the side of the retaining block 1. A pulley 15 is attached to the output shaft of the motor 14, and a belt 16 is installed between the pulley 15 and the pulley 12 which is on the central shaft 5.
Guide rods 17 are installed vertically on the upper surface of the retaining block 1. A pressure application block 19, to which pressure is applied as indicated by arrow 18 via a pressure means which is not shown in the drawings, is provided on the upper ends of the guide rods 17 via bearings 20. The pressure application block 19 is thus movable up and down.
A method of accomplishing a parallel alignment of the undersurface of the bonding tool 7 will be described below.
Before the adjustment operation starts, the vacuum suction applied to the suction adhesion holes 1c is "off". In this state, the central shaft 5 is kept more or less in a vertical position by the springs 11. Thus, the central shaft 5 and therefore the bonding tool 7 are in a "free state", which means that the central shaft 5 and the bonding tool 7 can swing or incline in any direction. Keeping this "free state," the retaining block 1 is lowered so that the undersurface of the bonding tool 7 comes into contact with a bonding stage (not shown). Because of the looseness of the oscillating assembly 2 between the retaining block 1 and the holder 3, the undersurface of the bonding tool 7 by itself can conform to the bonding stage.
As a result, the upper surface of the oscillating assembly 2 is in tight contact with the spherical-surface indentation 1a of the retaining block 1. Then, vacuum suction that is to be applied to the suction adhesion holes 1c is activated. This causes the oscillating element 2 to be sucked by and retained in the retaining block 1 by the vacuum suction adhesion. In other words, the bonding tool 7 at the end of the central shaft 5 is fixed in position as set and aligned as described above.
As seen from the above, the oscillating assembly 2 to which the central shaft 5 is attached is provided in the retaining block 1 via a mechanism that can make an oscillation motion. Thus, the oscillating assembly 2 can oscillate relative to the retaining block 1. As a result, the undersurface of the bonding tool 7 can move in any desired direction.
Accordingly, a parallel alignment of the bonding tool 7 can be accomplished by first causing the undersurface of the bonding tool 7 to contact the bonding stage and then switching on the vacuum suction to be applied to the suction adhesion holes 1c after the oscillating assembly 2 has come into a tight contact with the retaining block 1. Thus, the adjustment operation is easily done in a short period of time.
After the parallel alignment of the bonding tool 7 has been accomplished, the motor 14 is rotated so that the position of the bonding tool 7 in the theta (θ) direction is adjusted. More specifically, when the motor 14 is toward, the central shaft 5 and the bonding tool 7 are also rotated via the pulley 15, belt 16 and pulley 12. The position of the bonding tool in the theta (θ) direction is thus adjusted.
Bonding load with which the bonding tool 7 presses against the workpiece is set by the use of the load cell 13. More specifically, the bonding load is provided by applying a pressure as indicated by arrow 18 to the pressure application block 19 by a means which is not shown in the drawings, thus pushing down the pressure application block 19 along the guide rods 17. As a result, the pressure is applied to the central shaft 5 and therefore to the bonding tool 7 via the load cell 13. The load in this case is detected by the load cell 13 and the bonding load is set accordingly.
FIG. 3 shows another embodiment of the present invention. In this embodiment, electromagnets are used. The electromagnets 25 are installed in the spherical-surface indentation 1a formed in the oscillating element retaining block 1. Magnetic plates 26 (iron plates, etc.) are attached to the surface of the oscillating assembly 2. Accordingly, when the electromagnets 25 are activated, the oscillating assembly 2 is retained by the retaining block 1. When the electromagnets 25 are switched off, the oscillating assembly 2 is back to the state to freely oscillate. This embodiment has the same effect and advantages as the first embodiment that uses vacuum suction.
FIG. 4 shows still another embodiment of the present invention. In the embodiments described in FIGS. 1 through 3, the rotation of the motor 14 is transmitted to the central shaft 5 via the pulley 15, belt 16 and pulley 12, thus adjusting the rotation of the bonding tool. In this embodiment shown in FIG. 4, however, the motor 14 that is for a rotary adjustment of the tool is directly connected to the central shaft 5 via a coupling 30.
It is preferable, in this embodiment, to use a coupling that has a spring structure capable of absorbing the upward and downward motion of the central shaft 5. Also in this embodiment, the load cell 13 is mounted on the upper surface of the retaining block 1. The thus structured device has the same effect as in the devices shown in FIGS. 1 through 3.
Reference numeral 5c is a disc secured to the central shaft 5. The disc 5c contacts the edge of a window le provided in the bottom of the retaining block 1. Because of this disc 5c secured to the central shaft 5, the springs 4 and holder 3 shown in FIGS. 1 through 3 are both eliminated. In this case, the undersurface of the oscillating assembly 2 does not need to be spherical. The oscillating element 2 can be cylindrical as indicated by the two-dot line in FIG. 4 with only the top portion thereof spherically shaped.
The device of FIG. 4 is drawn so that vacuum suction adhesion is used to retain the oscillating assembly 2 in the retaining block 1. However, it goes without saying that electromagnets 25 and magnetic plates 26 that are shown in FIG. 3 can also be used.
In all of the embodiments described above, adjustment of the position of the bonding tool 7 in the theta (θ) direction is accomplished by means of the motor 14. However, if a workpiece holder that carries the workpieces has a rotary mechanism, the motor 14 that is used for rotary adjustment of the tool can be omitted and the central shaft 5 is formed as an integral single element with the oscillating element 2.
In the present invention, as is clear from the above description, a parallel alignment of the undersurface of the bonding tool relative to a workpiece is accomplished by bringing the bonding tool into contact with the bonding stage and then switching on vacuum suction or electromagnets to positionally set the central shaft that has the bonding tool. Accordingly, the adjustment operation is easy and can be accomplished very quickly. Furthermore, since no slipping occurs between the bonding tool and the workpieces when the bonding tool comes into contact with the workpieces, there is no danger of improper contact. | A bonding head assembly including a retaining block having a vacuum suction hole or electromagnet on its concave surface formed on the undersurface, a central shaft loosely passing through the central hole of the retaining block and having a bonding tool at the lower end, an oscillating ball attached to the upper part of the central shaft. After the bonding tool is brought into in contact with a workpiece, vacuum suction or electromagnet is activated so that the oscillating ball is brought into a tight contact with the concave surface of the retaining block, thus securely retaining the oscillating ball in the retaining block and, as a result, setting the position of the central shaft and therefore the bonding tool. | 1 |
FIELD OF THE INVENTION
[0001] The present invention relates to methods of treating tumorous diseases using immunoglobulin molecules. In particular, the present invention relates to methods of treatment involving anti-EpCAM immunoglobulin molecules. The invention further relates to uses of such immunoglobulins in the production of medicaments. The invention further relates to immunoglobulin molecules which can be used treating tumorous diseases as well as compositions comprising such immunoglobulin molecules.
RELATED ART
[0002] In designing a therapeutic regimen involving the administration of immunoglobulin molecules, there are several factors which must be considered. On the one hand, the therapeutic immunoglobulin must be administered to a patient in a quantity sufficient to elicit the desired therapeutic effect. This effect should be realized upon initial treatment and should continue to be realized to as great an extent as possible as the immunoglobulin is progressively cleared from the patient's body in the time between two consecutive administrations. On the other hand, the amount of immunoglobulin administered must not be so great as to cause adverse and/or toxic side effects in the patient.
[0003] A problem therefore arises when the maximum dose of an immunoglobulin which can be tolerated without causing side effects (maximum tolerated dose, or “MTD”) limits the amount of immunoglobulin to a single-dose level which is insufficient to maintain, over time, the minimum level of immunoglobulin needed to ensure continued efficaciousness. In such a scenario, it becomes impossible to maintain the “serum trough level” needed to ensure a continued therapeutic effect until the next administration of immunoglobulin. The “serum trough level” of a medicament refers generally to the lowest concentration that medicament is allowed to reach at any time in a patient's blood without loss of therapeutic effect. It represents, then, the minimum amount of medicament which must always be present in the patient's blood in order for any therapeutic benefit to be realized.
[0004] Several approaches exist for maintaining a desired serum trough level of a therapeutic immunoglobulin. One approach is to increase the initial dose of the immunoglobulin to the patient. However, this approach has the disadvantage that the level of therapeutic immunoglobulin which is safe for the patient is likely to be exceeded and the patient is thus likely to experience adverse and/or toxic side effects.
[0005] Another approach is to increase the frequency of administration of the therapeutic immunoglobulin. However, an increased frequency of administration stands to severely detract from the patient's quality of life, as multiple and frequent visits to the clinic become necessary. This is especially the case when the illness to be treated is still in the early stages, and the patient would otherwise be able to lead a normal life.
[0006] Further, an increased application frequency implies a larger total amount of therapeutic immunoglobulin which is needed for a total therapeutic regimen. As such, an increased application frequency implies higher total costs associated with a given regimen of therapy as compared to a regimen of therapy in which the therapeutic immunoglobulin is administered less frequently.
[0007] In the event that the therapeutic immunoglobulin to be administered is specific for an antigen which is present in both healthy and diseased tissue, the antigen being more prevalent in diseased than in healthy tissue, it becomes all the more crucial to develop a treatment regimen which takes the above points into consideration. Here, the danger is especially great that too high or too frequent dosages will lead to undesired interaction between the therapeutic immunoglobulin and the antigen to which the therapeutic immunoglobulin specifically binds. These immunoglobulin-healthy tissue interactions stand to lead to adverse and/or toxic side effects which can complicate a regimen of therapy using the immunoglobulin.
[0008] One such antigen present both in healthy and diseased human tissue is the epithelial cell adhesion molecule (“EpCAM”, also called 17-1A antigen, KSA, EGP40, GA733-2, ks 1-4 and esa). EpCAM is a surface glycoprotein expressed by cells of simple epithelia and tumorous cells derived therefrom. Although the EpCAM molecule is displayed on the surface of cells from healthy tissue, its expression is up-regulated in malignant tissue. EpCAM serves to adhere to epithelial cells in an oriented and highly ordered fashion (Litvinov, J Cell Biol. 1997, 139, 1337-1348). Data from experiments with transgenic mice and rats expressing human EpCAM on their epithelia suggest that EpCAM on normal tissue may however not be accessible to systemically administered antibody (McLaughlin, Cancer Immunol. Immunother., 1999, 48, 303-311). Upon malignant transformation of epithelial cells the rapidly growing tumor cells are abandoning the high cellular order of epithelia. Consequently, the surface distribution of EpCAM becomes less restricted and the molecule better exposed on tumor cells. Due to their epithelial cell origin, tumor cells from most carcinomas still express EpCAM on their surface.
[0009] In the past, EpCAM has been shown to be a rewarding target for monoclonal immunoglobulin treatment of cancer, especially in patients with minimal residual disease suffering from disseminated tumor cells that may cause later solid metastases and thus worsen the patients' prognosis. In patients with minimal residual colorectal cancer, a murine monoclonal immunoglobulin specific for the EpCAM molecule decreased the 5-year mortality rate by 30% as compared to untreated patients, when applied systemically in five doses within four months after surgery of the primary tumor (Riethmüller, Lancet 343 (1994), 1177-83). More recently, strong EpCAM over-expression has been reported in about 40% patients with breast cancer and is associated with poor overall and disease-free survival (Spizzo et al., Int. J. Cancer 98 (2002), 883-8). Most recently, EpCAM expression was analyzed in 3,722 patients. It was found that EpCAM expression is very common in epithelial tumors, such expression having been observed in more than 88% of tumor samples. Specifically, EpCAM expression was observed in 94.1% of ovarian cancers, 94% of colon cancers, 92.3% of stomach cancers, 90.1% of prostrate cancers and 70.9% of lung cancers.
[0010] One example of a (murine) monoclonal antibody recognizing EpCAM is Edrecolomab (Panorex) (Koprowski, Somatic Cell Genet. 1979, 5, 957-971 and Herlyn, Cancer Res., 1980, 40, 717-721; incorporated by reference in its entirety). However, the first administration of Panorex during adjuvant immunotherapy of colon cancer led to the development and exacerbation of Wegener's granulomatosis suggesting that Panorex should be applied cautiously in a patient with autoimmune disease (Franz, Onkologie 2000, 23, 472-474; incorporated by reference in its entirety). The limitations of Panorex are the rapid formation of human anti-mouse antibodies (HAMA), the limited ability to interact by its murine IgG2a Fey receptor with human immune effector mechanisms and the short half-life in circulation (Frodin, Cancer Res., 1990, 50, 4866-4871; incorporated by reference in its entirety). Furthermore, the murine antibody caused immediate-type allergic reactions and anaphylaxis upon repeated injection in patients (Riethmüller, Lancet 1994, 343, 1177-1183, Riethmüller, J Clin Oncol., 1998, 16, 1788-1794 and Mellstedt, Annals New York Academy of Sciences 2000, 910, 254-261; each incorporated by reference in their entirety).
[0011] ING-1 is another known anti-EpCAM immunoglobulin (Lewis, Curr. Op. Mol. Ther. 5, 433-6, 2003; incorporated by reference in its entirety). ING-1 is a mouse-human chimeric IgG1 immunoglobulin currently in Phase I/II clinical studies of patients with advanced epithelial tumors. While a dose of 1 mg/kg of immunoglobulin was found to provide the greatest effect in mice which had been pre-injected with human tumor cells, this dosage led to pancreatitis in 2 out of 2 human patients with adenocarcinomas (amylase and lipase elevation with abdominal pain), precluding further dose escalation. The MTD for ING-1 was found to be only 0.3 mg/kg body weight, applied intravenously every 3 weeks. Considering that the ING-1 half-life at this dosage was about 31 hours and assuming that the average adult weighs 75 kg and has about 4.25 liters of blood, the serum level of ING-1 after 21 days (i.e., after 16.25 half-lives) would have decreased to below 7×10 −5 μg/mL blood, more than four orders of magnitude less than the 1 μg/mL serum level found to be necessary for maximum cytolytic effects. The MTD of ING-1 therefore prevents the necessary plasma trough level of anti-EpCAM immunoglobulin from being maintained.
[0012] There therefore exists a need for a treatment regimen involving anti-EpCAM antibodies which can be used for the treatment of cancer. Correspondingly, an aim of the present invention is to provide a treatment regimen involving anti-EpCAM immunoglobulins which overcomes the problems as outlined above.
SUMMARY OF THE INVENTION
[0013] The foregoing need is met by a method of treating tumorous disease in a human patient by administering to said patient a human immunoglobulin specifically binding to the human EpCAM antigen, said immunoglobulin exhibiting a serum half-life of at least 15 days, said method comprising the step of administering said immunoglobulin no more frequently than once every week.
[0014] Several advantageous effects are realizable by using an anti-EpCAM immunoglobulin with a serum half-life of at least 15 days. Most importantly, this relatively long serum half-life implies that the anti-EpCAM immunoglobulin administered as part of the inventive method will not be cleared from the blood as rapidly as another immunoglobulin with a shorter half-life, say that of IMG-1 as discussed above. Assuming, then, that an anti-EpCAM immunoglobulin fulfilling the requirements of the immunoglobulin to be used in the method of the invention and an anti-EpCAM immunoglobulin not fulfilling these requirements are both administered to a human simultaneously and in identical absolute amounts, more of the former immunoglobulin will persist in the serum after a given time than the latter immunoglobulin. In a converse sense, the enhanced persistence in the serum allows less of the anti-EpCAM immunoglobulin used in the inventive method to be administered at one time than would be possible for another anti-EpCAM of shorter serum half life while still maintaining a certain predetermined serum trough level, i.e., while ensuring that the total serum concentration of therapeutic agent never drops below the minimum level determined to be necessary for continued efficacy between two consecutive administrations. This has the advantageous effect that less of the anti-EpCAM immunoglobulin of the method of the invention need be applied in any given dose, thereby eliminating the possibility of or at least mitigating any adverse and/or toxic side effects.
[0015] The relatively long half-life of the anti-EpCAM immunoglobulin as used in the method of the invention also implies that administration need not take place too frequently, thereby increasing the quality of life for the patient and reducing total cost of therapy.
[0016] That the anti-EpCAM immunoglobulin used in the method of the invention is a human immunoglobulin reduces or even eliminates the possibility of an undesired immune response mounted by the patient's immune system against the administered immunoglobulin. As such the problems associated with human anti-mouse antibodies (“HAMAs”) observed when using many murine or even murine-human chimeric immunoglobulin molecules in therapy do not pose a problem according to the inventive method.
[0017] While not being bound by theory, the inventors believe that an anti-EpCAM immunoglobulin as used in this aspect of the invention elicits a therapeutic effect based on at least one of two different mechanisms in vivo. One mechanism is known as antibody-dependent cellular cytotoxicity (“ADCC”). In ADCC, a cell (“target cell”) which is coated with immunoglobulin is killed by a cell (“effector cell”) with Fc receptors which recognize the Fc portion of the immunoglobulin coating the target cell. In most cases, the effector cells participating in ADCC are natural killer (“NK”) cells which bear on their surface either the Fc receptor Fc-□-RIII and/or the molecule CD16. In this way, only cells coated with immunoglobulin are killed, so the specificity of cell killing correlates directly with the binding specificity—here, EpCAM—of the immunoglobulin coating such cells.
[0018] Another mechanism by which the immunoglobulin as used in this aspect of the invention elicits a therapeutic effect is known as complement-dependent cytotoxicity (“CDC”). In CDC, two identical immunoglobulins bind to two identical antigens (for example, here EpCAM) on the surface of a target cell such that their respective Fc portions come into close proximity to one another. This scenario attracts complement proteins, among them complement proteins c1q and c3 and c9, the latter of which creates a pore in the target cell. The target cell is killed by this perforation. At the same time, the target cell/s also become/s decorated at other locations on its/their surface/s in a process called opsonization. This decoration attracts effector cells, which then kill the target cell/s in a manner analogous to that described above in the context of the ADCC mechanism.
[0019] By virtue of the long half life of the immunoglobulin used in the method according to this aspect of the invention, the benefit of one or both of the above mechanisms may be exploited for a longer time, and at higher levels, than possible using an anti-EpCAM immunoglobulin with a shorter half life.
[0020] According to this aspect of the invention, the anti-EpCAM immunoglobulin is administered to a patient no more frequently than once every week, preferably no more frequently than once every two weeks. In this respect, the advantageously long serum half-life of the anti-EpCAM immunoglobulin is exploited. In the event that the administration takes place once every week, only small amounts of immunoglobulin will need to be administered in any one administration, as more than half of the previously administered immunoglobulin will still persist in the blood of the patient. This is because one week is less than the approximately 15-day half life of the immunoglobulin previously administered.
[0021] In the event that the administration takes place about once every two weeks, the dosing frequency according to the inventive method corresponds approximately to the half life of the immunoglobulin. As such, the serum level of this immunoglobulin in the interim between two consecutive administrations will never have decreased by more than about one-half its amount immediately following the respective previous administration. This means that the dosage of any given administration need be no higher than the amount required to lead, immediately after administration, to approximately two times the predetermined serum trough level reached by the time of the next administration.
[0022] Generally, one may define two phases of administration: a first “loading phase” in which one or more loading doses is/are administered so as to reach a certain steady plasma level of immunoglobulin, and a subsequent “maintenance phase” in which multiple maintenance doses are administered so as to maintain the desired immunoglobulin plasma level. The loading dose(s) is/are typically administered in higher amount and/or in more frequent succession than the later maintenance doses, thus keeping the duration of the loading phase to a minimum.
[0023] According to present dosing regimens not corresponding to the present aspect of the invention, the medical practitioner is faced with two choices: Either the anti-EpCAM immunoglobulin is administered in a high enough initial amount to ensure, following its rapid clearance from the body, that the serum trough level is maintained before the next administration (in which case the high initial dose is likely to cause adverse and/or toxic side effects such as pancreatitis); or the anti-EpCAM immunoglobulin is administered in a low enough initial amount to avoid adverse and/or toxic side effects (in which case the serum level of anti-EpCAM immunoglobulin drops below the serum trough level before the next administration, leading to a loss of therapeutic effect). The compromise is to increase the frequency of administration of the low dosage, leading to a significant loss of quality of life for the patient.
[0024] In contrast, the method according to this aspect of the invention strikes a balance in which, on the one hand, individual doses may be administered in amounts which do not lead to adverse and/or toxic side effects and, on the other hand, the amount of therapeutic immunoglobulin in the serum does not drop below the serum trough level required for continued therapeutic effect between consecutive administrations. The rhythm of at least about one week between two consecutive administrations, preferably at least about two weeks between two consecutive administrations, allows this balance while not unduly impairing the quality of life for the patient.
[0025] According to one embodiment of the invention, the serum level of the anti-EpCAM antibody still present from a previous administration is checked in the patient's blood prior to effecting a next administration. In this way, the medical practitioner can avoid re-administering the anti-EpCAM immunoglobulin too early, as would for example be the case if there still existed ample anti-EpCAM immunoglobulin in the patient's blood from the previous administration. Accidental overdosing, which may lead to adverse and/or toxic side effects, is thus avoided for an anti-EpCAM antibody for which the exact half life is not yet known. At the same time, the medical practitioner gains valuable knowledge regarding the clearance rate of the anti-EpCAM immunoglobulin used from such an interim measurement, which in any case occurs at least two weeks following a respective prior administration. This knowledge can be valuable in fine-tuning the further administration schedule. Such fine tuning may advantageously entail waiting significantly longer than one week, or preferably longer than about two weeks, between consecutive administrations, thereby further increasing the patient's quality of life.
[0026] Advantageously, such interim checking of serum level of the anti-EpCAM immunoglobulin in the patients blood may be performed in the following manner. First, the medical practitioner may determine, after a period of at least one week following a respective last administration of said immunoglobulin but prior to a respective next administration of said immunoglobulin, the serum level of said immunoglobulin still present in the blood of said patient, thereby obtaining an intermediate serum level value for said immunoglobulin. This intermediate serum level value for said immunoglobulin is then compared with a predetermined serum trough level value for said immunoglobulin. If the intermediate serum level value for said immunoglobulin is found to be well above the predetermined serum trough level for said immunoglobulin, then the medical practitioner may advantageously elect to wait even longer for the serum level of the anti-EpCAM immunoglobulin to decrease further. At this time, the above steps may be repeated in order to obtain a new intermediate serum level of said immunoglobulin, which will then have decreased to a value closer to the predetermined serum trough level. In any case, one should not wait so long that the intermediate serum level determined for the immunoglobulin sinks below the predetermined serum trough level for that immunoglobulin. When the medical practitioner establishes, possibly by repeated cycles of waiting, determining intermediate serum level, and comparing this intermediate serum level to the predetermined serum trough level for a particular anti-EpCAM immunoglobulin, that the intermediate serum level of this immunoglobulin has decreased to within a certain percentage of said serum trough level, the respective next administration of the anti-EpCAM immunoglobulin may be effected to bring the serum level of the anti-EpCAM immunoglobulin back up to an appropriate level for the next round of clearance. Advantageously, this certain percentage may correspond to a serum level which is within 15%, preferably within 10%, most preferably within 5% of the predetermined serum trough level for the particular anti-EpCAM immunoglobulin used.
[0027] Advantageously, intermediate immunoglobulin serum level may be measured by any method known to one of ordinary skill in the art, for example, by immunoassay. For example, an immunofluorescence assay, a radioimmunoassay or an enzyme-linked immunosorbent assay—ELISA assay may be used for this purpose, the latter being preferred.
[0028] In a preferred embodiment of this aspect of the invention, the human anti-EpCAM immunoglobulin is administered no more frequently than once every two weeks. In an especially preferred embodiment, administration takes place in intervals of two weeks, wherein each subsequent dose is equivalent in amount to the first dose administered, i.e., all doses are made in the same amount. Administration in this way is sufficient to maintain a serum level of immunoglobulin which never drops below the predetermined serum trough level required for a beneficial therapeutic effect of this immunoglobulin, while at the same time avoiding, or largely avoiding adverse and/or toxic side effects.
[0029] However, in another embodiment it is also envisioned that administration frequencies of more than, or much more than two weeks are possible. In the event that the immunoglobulin is administered in time intervals greater than two weeks, the amount of antibody administered at any time subsequently to the initial dose should be greater than an initial dose made in expectation of a subsequent administration in two weeks. The amount by which such a subsequent dose administered after more than two weeks may be greater than a dose administered after two weeks may be determined on a case by case basis, for example by means of pharmacokinetic simulations (e.g., with WinNonlin 4.0.1 (Pharsight Corporation, USA; 2001) such as those described in the examples appended to the foregoing description. One of ordinary skill in the art understands how to construct and/or apply such simulations. Such simulations are advantageously constructed such that, after a respective administration, the level of anti-EpCAM immunoglobulin in the patient's serum is not allowed to drop below the serum trough level determined to be necessary for therapeutic efficacy.
[0030] The long serum half life of the human anti-EpCAM immunoglobulin ensures that over this longer period between administrations, say three or even four weeks or any intermediate period from 2 to 5 weeks, the predetermined serum trough level required for therapeutic efficacy is maintained. In other words, the long serum half life of the human anti-EpCAM immunoglobulin (i.e., about 15 days) ensures that a significant quantity of this immunoglobulin will still be present in the serum from a respective previous administration. As a result, less of the human anti-EpCAM immunoglobulin with the half life of about 15 days need be applied than would be necessary for an antibody without such a long serum half life. This reduces the risk of adverse and/or toxic side effects.
[0031] It should be noted that such protracted administration schemes—and the multiple advantages associated therewith (see above)—would be impossible with an anti-EpCAM immunoglobulin with a short half life, while still maintaining therapeutic effect (for example with the anti-EpCAM immunoglobulin ING-1, for which the serum half life in humans ranging from 17 to 31 hours has been measured). To ensure that at least the predetermined serum trough level amount of such an anti-EpCAM immunoglobulin would persist in the serum until the following administration, so much anti-EpCAM immunoglobulin would have to be administered that adverse and/or toxic side effects would very likely be encountered. On the other hand, avoiding such adverse and/or toxic side effects by administering less of such a short-lived anti-EpCAM immunoglobulin would lead to loss of therapeutic effect at some point between the two administrations when the amount of immunoglobulin persisting in the blood sinks below the serum trough level.
[0032] Of course, if determined clinically necessary or advantageous, a human anti-EpCAM immunoglobulin with a serum half life of about 15 days may in a further embodiment be administered in time intervals of less that two weeks, say in intervals of 1 week or any intermediate period from 1 week to 2 weeks. While such a scenario does not fully exploit the long serum half life of about 15 days, there are nevertheless clinical situations in which such an administration may be desirable. In order to avoid an unwanted accumulation of the human anti-EpCAM immunoglobulin in the patient over time, it is preferable here to reduce the amount of human anti-EpCAM administered in these shorter intervals relative to the amount which would need to be administered in a bi-weekly administration rhythm. The amount by which such a subsequent dose administered after less than two weeks must be less than a dose administered after two weeks may be determined on a case by case basis, for example by means of pharmacokinetic simulations such as those described in the examples appended to the foregoing description. One of ordinary skill in the art understands how to construct and/or apply such simulations. Such simulations are advantageously constructed such that, after a respective administration, the level of anti-EpCAM immunoglobulin in the patient's serum is not allowed to drop below the serum trough level determined to be necessary for therapeutic efficacy.
[0033] According to one embodiment, the administration may be intravenous, intraperitoneal, subcutaneous, intramuscular, topical or intradermal. Alternatively, a combination of these administration methods may be used as appropriate. Further envisaged are co-administration protocols with other compounds, e.g., bispecific antibody constructs, targeted toxins or other compounds, which act via T cells or other compounds such as antineoplastic agents which act via other mechanisms. The clinical regimen for co-administration of the anti-EpCAM immunoglobulin may encompass co-administration at the same time, before or after the administration of the other component.
[0034] Advantageously, the tumorous disease is chosen from breast cancer, epithelial cancer, hepatocellular carcinoma, cholangiocellular cancer, stomach cancer, colon cancer, prostate cancer, head and neck cancer, skin cancer (melanoma), a cancer of the urogenital tract, e.g., ovarian cancer, endometrial cancer, cervix cancer, and kidney cancer; lung cancer, gastric cancer, a cancer of the small intestine, liver cancer, pancreas cancer, gall bladder cancer, a cancer of the bile duct, esophagus cancer, a cancer of the salivatory glands or a cancer of the thyroid gland.
[0035] In another embodiment, the disease may also be a minimal residual disease, preferably early solid tumor, advanced solid tumor or metastatic solid tumor, which is characterized by the local and non-local reoccurrence of the tumor caused by the survival of single cells.
[0036] In an especially preferred embodiment of this aspect of the invention, the tumorous disease is prostate cancer or breast cancer. Here, it is especially preferred that the human anti-EpCAM immunoglobulin administered is one which comprises an immunoglobulin heavy chain with an amino acid sequence as set out in SEQ ID NO: 1 and an immunoglobulin light chain with an amino acid sequence as set out in SEQ ID NO: 2. When such a human anti-EpCAM immunoglobulin is administered, it is preferable that it be administered in a respective amount of dosage of 1-7 mg/kg body weight, even more preferably 2-6 mg/kg body weight about once every two weeks.
[0037] A further aspect of the invention provides a use of a human immunoglobulin specifically binding to the human EpCAM antigen, said immunoglobulin exhibiting a serum half life of at least 15 days, for the preparation of a medicament for treating tumorous diseases. Alternatively, a composition comprising such an immunoglobulin may be used for preparing the above medicament. The medicament may then be advantageously administered according to the dosage schedule outlined above for the method of treatment of a tumorous disease.
[0038] According to one embodiment of this aspect of the invention, the medicament prepared is suitable for administration by an intravenous, an intraperitoneal, a subcutaneous, an intramuscular, a topical or an intradermal route. Alternatively, administration may take place by a combination of more than one of these routes as appropriate. Further envisaged are co-administration protocols with other compounds, e.g., bispecific antibody constructs, targeted toxins or other compounds, which act via T cells or other compounds such as antineoplastic agents which act via other mechanisms. The clinical regimen for co-administration of the anti-EpCAM immunoglobulin may encompass co-administration at the same time, before or after the administration of the other component.
[0039] Advantageously, the tumorous disease is breast cancer, epithelial cancer, hepatocellular carcinoma, cholangiocellular cancer, stomach cancer, colon cancer, prostate cancer, head and neck cancer, skin cancer (melanoma), a cancer of the urogenital tract, e.g., ovarian cancer, endometrial cancer, cervix cancer, and kidney cancer; lung cancer, gastric cancer, a cancer of the small intestine, liver cancer, pancreas cancer, gall bladder cancer, a cancer of the bile duct, esophagus cancer, a cancer of the salivatory glands or a cancer of the thyroid gland.
[0040] In another embodiment, the disease may also be a minimal residual disease, preferably early solid tumor, advanced solid tumor or metastatic solid tumor, which is characterized by the local and non-local reoccurrance of the tumor caused by the survival of single cells.
[0041] In a further aspect, the invention relates to a human immunoglobulin specifically binding to the human EpCAM antigen, characterized in that said immunoglobulin exhibits a serum half-life of at least 15 days after administration to a human patient. The advantages associated with such a long serum half life have been elaborated above, within the framework of such an antibody's use in a method of treatment for tumorous diseases. It is preferred that the immunoglobulin exhibits a serum half life of 20 days, 19 days, 18 days, 17 days, 16 days or 15 days. Especially preferred is a serum half life of about 15 days.
[0042] According to a preferred embodiment of the invention, the half life of the human immunoglobulin is 15 days and the human immunoglobulin comprises an immunoglobulin heavy chain with an amino acid sequence as set out in SEQ ID NO: 1 and an immunoglobulin light chain with an amino acid sequence as set out in SEQ ID NO: 2.
[0043] A further aspect of the invention provides a composition comprising a human anti-EpCAM immunoglobulin as described above. Such a composition may advantageously be administered to a human patient as part of a regimen of therapy for treating a disease. In view of the prevalence of expression of the EpCAM molecule in tumorous diseases, it is especially preferred that such a composition may be administered as part of a therapeutic regimen aimed at treating such a tumorous disease. Tumorous diseases which may advantageously be treated by administration of such a composition according to this aspect of the invention include breast cancer, epithelial cancer, hepatocellular carcinoma, cholangiocellular cancer, stomach cancer, colon cancer, prostate cancer, head and neck cancer, skin cancer (melanoma), a cancer of the urogenital tract, e.g., ovarian cancer, endometrial cancer, cervix cancer, and kidney cancer; lung cancer, gastric cancer, a cancer of the small intestine, liver cancer, pancreas cancer, gall bladder cancer, a cancer of the bile duct, esophagus cancer, a cancer of the salivatory glands or a cancer of the thyroid gland.
[0044] In another embodiment, the disease may also be a minimal residual disease, preferably early solid tumor, advanced solid tumor or metastatic solid tumor, which is characterized by the local and non-local reoccurrence of the tumor caused by the survival of single cells.
[0045] It is within this aspect of the invention that such tumorous diseases may be treated either alone or in combination, a combination of such diseases having for example arisen due to metastatic spreading of a primary tumorous disease to lead to a or multiple secondary tumorous disease(s).
[0046] As used herein, the terms “antibody”, “antibody molecule”, “img” and “img molecule” are to be understood as equivalent. Where appropriate, any use of the plural implies the singular, and any use of the singular implies the plural.
BRIEF DESCRIPTION OF THE DRAWINGS
[0047] The following drawings form part of the present specification and are included to further demonstrate certain aspects of the present invention. The invention may be better understood by reference to one or more of these drawings in combination with the detailed description of specific embodiments presented herein.
[0048] FIG. 1 Dosing schemes for Phase I cohorts
[0049] FIG. 2 Plasma concentration of anti-EpCAM immunoglobulin vs. time, per cohort
[0050] FIG. 3 pharmacokinetic parameters of patient cohorts after single dose of anti-EpCAM immunoglobulin
[0051] FIG. 4 pharmacokinetic parameters of patient cohorts after multiple doses of anti-EpCAM immunoglobulin
[0052] FIG. 5 Schematic representation of three-compartment model
[0053] FIG. 6 Peak and trough plasma levels of anti-EpCAM immunoglobulin with target trough level of 30 μg/mL
[0054] FIG. 7 Peak and trough plasma levels of anti-EpCAM immunoglobulin with target trough level of 10 μg/mL
[0055] FIGS. 8A-F Immunohistological staining of EpCAM-expressing tissues
[0056] FIG. 9 Median values of EpCAM semi-quantitative histological scores in patients with various liver diseases.
[0057] FIG. 10 Depicts as points the individual trough levels measured for one patient from the low-dosage group (patient number 401001; data points indicated by squares) and another patient from the high-dosage group (patient number 101002; data points indicated by diamonds).
DETAILED DESCRIPTION OF THE INVENTION
[0058] The following examples are included to demonstrate preferred embodiments of the invention. It should be appreciated by those of skill in the art that the techniques disclosed in the examples which follow represent techniques discovered by the inventors to function well in the practice of the invention, and thus can be considered to constitute preferred modes for its practice. However, those of skill in the art should, in light of the present disclosure, appreciate that many changes can be made in the specific embodiments which are disclosed and still obtain a like or similar result without departing from the spirit and scope of the invention.
Example 1
Acquisition of Pharmacokinetic Data Measured in the Phase I Study
[0059] Cohorts. The pharmacokinetics of an anti-EpCAM immunoglobulin characterized by SEQ ID NOs: 1 and 2 (hereinafter “Anti-EpCAM”) were investigated in patients with hormone refractory prostate cancer following two single intravenous infusions at a time interval of 14 days. The administered dosages were 10, 20, 40, 64, 102, 164 and 262 mg/m 2 body surface area. Two or three patients at each dose level were treated on day 1 and day 15. Blood samples were taken at 29-31 sampling time points from day 1 to day 70 (56 days after second administration). The serum concentrations of Anti-EpCAM were measured by a specific ELISA method. The ELISA was set up as a typical sandwich ELISA, in which a rat anti-Anti-EpCAM antibody was used as the capture antibody and a chicken anti-Anti-EpCAM antibody as the detection antibody (as described in Sambrook, Molecular Cloning, Cold Spring Harbor Laboratory Press). The dosing schemes used for the Phase I patient cohorts are shown in FIG. 1 . The symbol “˜” in column 3 of FIG. 1 denotes that the values calculated for the doses, carrying the units mg/kg, are the result of average doses (taken over the number of patients in the respective cohort) divided by the average body weight (also taken over the number of patients in the respective cohort). As such, a respective dosage value represents the quotient of two average values.
[0060] Serum Concentrations. The serum levels of Anti-EpCAM (mean values±SD from 2-3 determinations) were measured in the individual patients after two single intravenous infusions of Anti-EpCAM. A comparison of the individual profiles within the single cohorts are presented in FIG. 2 . The mean concentration/time profiles (arithmetic means) obtained for all dose groups of patients with hormone refractory prostate cancer following two single intravenous infusions at an time interval of 14 days are shown in FIG. 2 .
[0061] Simplified Dosage Scheme. Patients received a personalized dosage, which was calculated in mg Anti-EpCAM /m 2 body surface area. Due to the consistency of the serum profiles observed for the different patients within one dose group, it was analyzed whether a simplification of the dosage scheme would be feasible. For this purpose, the profiles of the cohorts 5, 6 and 7 were normalized to an equal total dose of 500 mg and the results compared with respect to the variability of the serum levels.
[0062] For the 9 patients, the dose normalization to 500 mg total dose led to serum levels varying by a mean coefficient (% CV) of 26.6%. The coefficient of variation ranged from 14.8 to 67.3%, the highest variation was observed at lower serum levels. Based on these results, a simplification of the dose regimen to a total dose was considered to be feasible.
[0063] Pharmacokinetics: Non-Compartmental Evaluation. A summary of the main pharmacokinetic parameters (arithmetic means) calculated for patients of all seven cohorts with hormone refractory prostate cancer following the first intravenous infusion (single dose) of Anti-EpCAM is presented in FIG. 3 . The main pharmacokinetic parameters (arithmetic means) of Anti-EpCAM after the second intravenous administration (multiple dose) on day 14 is shown in FIG. 4 .
[0064] Definitions of terms used in FIGS. 3 and 4 are as follows. C max refers to the maximum (measured) concentration. AUC τ refers to the area under the concentration/time curve (AUC) observed in one dose interval (τ=14 days) calculated with the trapezoidal rule from 14 to 28 days (for multiple dose). AUC INF refers to the AUC calculated using the trapezoidal rule from 0 hours to infinity according to the formula AUC∞=AUCz+Cz/ke. t½ refers to the mean apparent terminal half-life (1n2/λz), wherein the term “mean” refers to the averaging of multiple values determined for serum half life; the term “apparent” refers to extrapolation of a curve fit to selected pharmacokinetic values to an infinite time point such that the amount of immunoglobulin present in a patient's serum at infinite time decays asymptotically to zero; and the term “terminal” refers to this infinite time point. The parameter τ is a standard pharmacokinetic parameter used as a constant multiplication factor, and the parameter z denotes any time point z. Cl ss refers to the total body clearance, calculated according to the formula Dose/AUC. V ss refers to the apparent volume of distribution. Vz refers to the mean volume of distribution. CL refers to the mean volume of clearance.
[0065] The mean apparent terminal half-life (t½) was determined to be 6.72±0.88 days after single dose (calculated from 7-14 days) and 14.74±4.23 days after multiple dose administration (calculated from the last three sampling points, i.e., 28-42 days or 35-70 days). The differing half-life values are due to the clearly longer observation period after the second dose, measured half life values becoming more accurate the longer values are measured due to improved goodness of curve fit. As such, the value for t½ of 14.74±4.23 days represents the more accurate value for t½, since it was measured over a long period of time.
[0066] After the first administration a Vz of 10.4 L and a mean volume of clearance of 1.1 L/day was determined. These data are well in accordance with the results calculated for the second dose with a mean Vz of 11.5 L and a mean volume of clearance (CL) of 1.0 L/day. Moreover these data are well comparable between all dose groups (coefficient of variation from 8.2 to 14.8%). As a result, dose-dependency was observed neither for the parameter Vz nor for the parameter CL.
[0067] Dose Linearity. The dose relationship regarding the parameters C max , AUC last(0-14) /AUC τ(14-28) and AUC inf were determined. For all parameters (C max , AUC last(0-14) /AUC τ(14-28) and AUC inf ) one may assume a dose-linear increase in the investigated dose range.
[0068] Pharmacokinetics: Compartmental Evaluation. The compartmental analysis was based on two different models requiring a constant infusion of the drug. For the assessment of the best compartmental model the data obtained from cohort 6 relating to mean concentration vs. time was chosen. For both evaluations the profile after the second dose was applied due to the longer observation time after administration.
[0069] In order to investigate the best fit, the following compartmental models were employed:
2-Compartment Evaluation 3-Compartment Evaluation
With both models, an evaluation was possible, however, a clearly better fit was obtained with the 3-compartment analysis. The congruence between observed Y and predicted Y was noticeably better after 3-compartmental analysis. For this reason, all further evaluations were performed on the basis of this 3-compartmental model.
[0072] The pharmacokinetics of Anti-EpCAM were investigated in patients following intravenous short-term infusion of 10, 20, 40, 102, 164 and 262 mg/m 2 body surface area. Two or three patients per cohort were treated. Blood samples were taken over a time period of 42 or 70 days. The serum concentrations of Anti-EpCAM were measured by an ELISA method. Complete serum profiles up to 42 or 70 days could be obtained and evaluated for all patients.
[0073] Volume of clearance and volume of distribution showed no dose dependency and no major differences after the first and the second dose. Based on the data from 7 cohorts, dose-linearity for the parameters C max , AUC τ1 , and AUC inf in the investigated dosage range can be assumed.
[0074] Compartmental analysis showed a third-order decline of Anti-EpCAM serum concentrations with half-lives of 0.565 days (t 1/2α ), 3.78 (t 1/2β ) and 13.3 days (t 1/2λz ).
[0075] As expected from the terminal half-life (approximately two weeks), the simulations of various dose regimens produced the best results for a biweekly design. The simulation of a weekly dose led to an accumulation whereas the administration every 4 weeks resulted in a decrease of Anti-EpCAM serum levels. In view of reaching the target trough levels as fast as possible, a loading dose with the double amount compared to the maintenance dose is recommended.
Example 2
Modeling of Anti-EpCAM Dosing Strategy Based on Measured Data Obtained in the Phase I Study
[0076] The dosage regimen and treatment duration selected for this study are based on pharmacokinetic modeling of the results of the phase I/II clinical study with Anti-EpCAM in patients with prostate cancer. The objective of the simulations was to find a dosing schedule for Anti-EpCAM to achieve serum trough levels of 10 and 30 μg/mL, respectively.
[0077] Based on preclinical experiments, serum trough levels of 10 μg/mL are expected to be effective for anti-tumor activity of Anti-EpCAM. However, it cannot be ruled out that higher doses might be more effective. Therefore, a second dose, calculated to achieve serum trough level of 30 μg/mL, is to be evaluated in clinical trials. No additional toxicity is expected with this serum trough concentration as Cmax and AUC values do not exceed the ones observed in phase I clinical studies.
[0078] Due to the better fit, all simulations were based on the 3-compartmental evaluation data from cohorts 5 to 7.
[0079] The aim of the simulations was to assess the optimum administration scheme and the required dose in consideration of frequency (weekly, biweekly, every 4 weeks), different trough levels (10 μg/mL, 30 μg/mL Anti-EpCAM) and to evaluate the benefit of a loading dose of Anti-EpCAM.
[0080] As expected from the terminal half-life value of ca. two weeks, the biweekly dosage regimen led to the best results. Applying an administration frequency of 7 days and 28 days, the simulation resulted in an accumulation or a slight decrease of serum levels, respectively. The application of a loading dose (LD) led to immediate attainment of the required trough levels. The following doses and corresponding minimum and maximum serum levels were simulated for intravenous administration of Anti-EpCAM.
[0081] Administration every 14 days. As expected from the terminal half-life of Anti-EpCAM, the biweekly administration resulted in simulated profiles with constant C min and C max values and therefore can be regarded as the recommended dosage regimen. Therefore, the biweekly model was chosen for the calculation of the required dosages leading to target trough levels of 10 and 30 μg/mL of Anti-EpCAM.
[0082] The initial parameters for the calculations were gained by a compartmental evaluation.
Study data: Pharmacokinetic measurements obtained in the Prostate Cancer Phase I/II Study. Software: WinNonlin 4.0.1 (Pharsight Corporation, USA; 2001) Model: PK Model 19 (3 compartment IV-Infusion, macro-constants, no lag time, 1st order elimination, uniform weighting).
FIG. 5 is a schematic representation of the three compartment model, where ‘1’ represents the central compartment and ‘2’ and ‘3’ represent two different peripheral compartments. The central compartment is in immediate equilibrium with the plasma. The peripheral compartment requires some time to reach an equilibrium with the central compartment following an administration of a drug. K13, K31, K12, K21, K10 are the respective velocity constants, wherein the order of the numerals 13, 31, etc. denotes the direction of passage of Anti-EpCAM.
[0086] The simulations were extended to a period of 120 days, although the original study data were limited to a period of 70 days. The simulations were based on a loading phase (i.e., administration of drug on days 1, 8, and 15) and a maintenance phase (i.e., administration of drug on days 29 and every 14 days thereafter):
Group A (low dose): loading phase of 2 mg Anti-EpCAM/kg body weight weekly (days 1, 8, 15), followed by 23 maintenance doses of 2 mg Anti-EpCAM/kg body weight every second week Group B (high dose): loading phase of 6 mg Anti-EpCAM/kg body weight weekly (days 1, 8, 15), followed by 23 maintenance doses of 6 mg Anti-EpCAM/kg body weight every second week.
The doses intended in this study lead to pharmacokinetic parameters (i.e., C max and AUC) that do not exceed those measured with the highest doses administered to patients in the phase I study. Loading phases and maintenance phases have been calculated using pharmacokinetic modeling to achieve targeted serum trough concentrations within a short period of time and to avoid maximum plasma concentrations that would exceed the ones assessed in the phase I study.
[0089] FIG. 6 shows a simulation of a biweekly administration described above of Anti-EpCAM including a loading phase with a target serum trough level of 30 μg/mL. FIG. 7 shows a simulation of a biweekly administration of Anti-EpCAM described above including a loading phase with a target serum trough level of 10 μg/mL.
[0090] FIGS. 6 and 7 show the respective administrations of drug over a time scale of 120 days. Peak and trough serum concentrations can be seen, the peak levels being represented by the upper portions of the curve and trough levels being represented by the lower part of the curves. Graphs represent the simulations to reach the above-mentioned different trough levels of 10 and 30 μg/ml, respectively. As can be seen from the figures, the peak and trough serum concentrations are different in the two simulations.
Example 3
Anti-EpCAM Toxicity Data, Comparison with ING-1, Extrapolation
[0091] The following describes adverse events (AE) observed for the various patient cohorts. For the purposes of the following, an AE is defined as any untoward medical occurrence in a patient or clinical investigation subject to whom a pharmaceutical product is administered and which does not necessarily have a causal relationship with this treatment. It could therefore be any unfavorable and unintended sign (including abnormal laboratory findings), symptom, or disease temporally associated with the use of the investigational product, whether or not considered related to the investigational product.
[0092] Adverse drug reactions (i.e., AEs considered at least possibly related to study drug by the investigator) were graded by the investigator according to NCI Common Toxicity Criteria (CTC, version 2.0). For adverse drug reactions not listed on the NCI CTC tables, the general definitions for grading of severity of adverse events were to be followed. Accordingly, a “mild” AE describes a symptom which is barely noticeable to the patient. It does not interfere with the patient's usual activities or performance and/or it is of no clinical consequence. A “moderate” AE interferes with the usual activities of the subject and is sufficient enough to make the subject uncomfortable. It is of some clinical consequence; treatment for symptoms may be required. A “severe” AE is an event which causes severe discomfort and may be of such severity that the study treatment should be discontinued. The subject is unable to work normally or to carry out usual activities and/or the AE is of definite clinical consequence. Treatment for symptoms may be required. A “serious adverse event” (SAE) is defined as any untoward medical occurrence that, at any dose: Resulted in death, was life-threatening, required inpatient hospitalization or prolongation of existing hospitalization, resulted in persistent or significant disability/incapacity, or was a congenital anomaly/birth defect.
[0093] A total of 120 adverse events (AEs) regardless of relationship with study drug were reported in 19 (95%) patients during the treatment and the safety follow-up period of 28 days after the last infusion. More adverse events were reported in patients from cohort 6 (38 events) and in cohort 7 (35 events) compared to the lower dose cohorts (cohort 1: 7; cohort 2: 9; cohort 3: 12; cohort 4: 7; cohort 5: 12). The cohorts are set out in FIG. 1 , explained above in Example 1.
[0094] The most frequent treatment-emergent clinical AEs, regardless of the investigator's assessment of relation to study drug, were increase in body temperature (reported in 30% of all patients), nausea (30%), pyrexia (20%), diarrhea (15%), fatigue (15%), feeling cold (15%) and vomiting (15%). The most frequent treatment-emergent laboratory changes reported as adverse events, regardless of the investigator's assessment of relation to study drug, were elevated alkaline phosphatase (reported in 30% of all patients), lymphopenia (30%), elevated LDH (25%), PTT decrease (20%), hemoglobin decrease (20%), WBC disorders (15%), glycosuria (15%) and elevated transaminases (15%).
[0095] Most of the adverse events were mild (70%) or moderate (25%). Six severe adverse events (grade 3) were reported in four patients as follows: Elevated alkaline phosphatase in a patient with moderate (grade 2) value prior to treatment; Glycosuria in a patient with a known diabetes mellitus; One patient with decreased hemoglobin and RBC and weight loss; one patient with intervertebral disc herniation. None of the events was related to the study drug as assessed by the investigator. No grade 4 event was reported.
[0096] Four serious adverse events (SAE) were reported in 4 patients during the study period. One was considered possibly related to study medication by the investigator: a prolongation of hospitalization due to grade 1 fever after the 2nd infusion of Anti-EpCAM in a patient from Cohort 3 (40 mg/m 2 body surface area).
[0097] Clinical studies with the mouse-human chimeric, high-affinity (K D : 2×10 −9 ) anti-EpCAM antibody ING-1 resulted in pancreatitis at a dose of 1 mg/kg. These adverse events were dose dependent with a clear MTD. It is possible that the affinity of the immunoglobulin ING-1 towards the EpCAM antigen, higher by two orders of magnitude as compared to Anti-EpCAM, is related to the toxicity profile observed for ING-1. As the MTD of ING-1 (1 mg/kg) and the highest doses intended in the Anti-EpCAM protocol (6 mg/kg) are similar, it is expected that Anti-EpCAM, the immunoglobulin of the foregoing studies, has a significantly higher safety margin, possibly due to its much lower affinity.
Example 4
EpCAM Expression in Disease
[0098] In order to assess the range of applicability of the method of treatment described herein, the expression of the human EpCAM antigen was studied in a number of different diseases. It is expected that the method of the invention may be efficaciously applied to any disease in which EpCAM expression is elevated in the disease state relative to the healthy state of a given tissue. In particular, special attention was paid to the synthesis of the EpCAM antigen in liver tissue.
[0099] Patients and Tissues. Overall 254 different liver tissue specimens were characterized by immunohistology for EpCAM and for relevant morphological parameters as outlined below. Different tumor samples, including 63 HCCs, 5 cholangiocarcinomas of the liver, and 30 dysplastic nodules (pre-malignant hepatocellular precursor lesions), as well as 5 normal liver specimens were analyzed. 33 biopsies were taken from patients with chronic hepatitis C, 27 from patients with chronic hepatitis B, and 28 from those with chronic alcoholic liver disease (ALD); 9 patients had autoimmune hepatitis (AIH). Liver tissues were obtained by biopsy using a Menghini needle and in the case of HCCs by resection or liver explantation. Tissues were immediately fixed in 4% neutral buffered formaldehyde and processed according to standard protocols.
[0100] Morphological Evaluation. Morphological evaluation was performed on the basis of sections stained with H&E (grading of carcinomas and chronic hepatitis). Grading of HCCs was performed as outlined in Nzeako et al., Cancer 76, 1995, 579-88. Non-neoplastic liver diseases were morphologically evaluated as follows: Necroinflammatory activity of chronic hepatitis B and C cases was analyzed by using the modified hepatic activity index as described in Ishak, Mod. Pathol. 7, 1994, 690-713.
[0101] Immunohistological Evaluation. Immunohistology was performed as previously described (Prange et al., J. Pathol. 201, 2003, 250-9) using the so-called ABC method and diaminobenzidine as the chromogen. Mouse monoclonal anti-human EpCAM antibody (clone VU-1D9; Novocastra, Newcastle, UK) was diluted 1/50 and applied after 30 min trypsin pre-treatment (0.1%, pH 7.8). Immunohistology for cyclin D1 (DCS-6; 1:100; DAKO, Hamburg, Germany), p53 (FL-393; 1:50; Santa Cruz, Santa Cruz, USA), and ubiquitin (70458; 1:200; DAKO) was performed accordingly. Negative controls, including omission of the primary antibody were performed.
[0102] For evaluation of EpCAM staining in HCCs only intensity was graded semi-quantitatively (0=negative, +(1)=weakly positive, ++(2)=moderately positive, +++(3)=strongly positive (at least equal intensity as bile duct staining)). Hepatocellular expression of EpCAM in non-neoplastic biopsy specimen was graded as follows: 0=no hepatocellular staining; (+) (0.5)=few scattered positive hepatocytes, +(1)=small groups of hepatocytes along several or most septa or portal tracts, ++(2)=large groups of positive hepatocytes around several or most portal tracts or septa and extending into midacinar zone, +++(3)=extensive hepatocellular positivity, typically covering at least 50% of the acinus. Statistical evaluation was performed by using descriptive statistics (mean, median, maximum, frequency) and the correlation coefficient of Spearman. A level of p<0.05 was considered significant.
[0103] Neo-expression of EpCAM in HCCs. Normal liver tissue showed strong staining of all bile duct epithelia, while hepatocytes were completely negative (data not shown). Immunohistology for EpCAM showed specific membranous staining in 9 out of 63 analyzed HCCs (14.3%; FIGS. 8A-F ) and in all analyzed cholangiocarcinomas of the liver (n=5). In HCCs, expression ranged from weak to strong and appeared to be more frequent in moderately and poorly differentiated HCCs, while only one well differentiated HCC was positive. Also among 30 dysplastic nodules, which represent pre-malignant lesions, only 3 showed mild EpCAM expression. The same tissues were analyzed for numerous other tumor-relevant antigens and the expression data were submitted to correlative analyses. There was a moderate but significant positive correlation of EpCAM expression in HCCs with nuclear accumulation of p53 and ubiquitin (p<0.05), but not with the suspected upstream regulator cyclin D1.
[0104] Hepatocellular neo-expression of EpCAM in chronic necroinflammatory liver disease. Specific membranous positivity of hepatocytes was detected in a high percentage of the analyzed non-neoplastic liver tissues ( FIGS. 8C-E ). Marked positivity was found in cases with chronic hepatitis and to a lower extent in those with ALD. Furthermore, positivity of all ductular proliferations and also of single small cells dispersed in the periportal parenchyma (potential precursor cells) was noted. Hepatocellular positivity showed strong periportal/periseptal predominance and reached the intensity of bile duct staining in some of the cases. No specific reactivity for EpCAM was present in non-parenchymal liver cells in any of the cases.
[0105] When mean and median values of the semi-quantitative immunohistological score (see methods) were analysed, EpCAM expression was highest in tissues with HBV-infection (mean score: 0.93; median score: 0.5; maximal score: 3; frequency of positive EpCAM staining (+/++/+++): 55.6%;), ALD (mean score: 0.88; median score: 0.75; maximal score: 2.5; frequency of positive EpCAM staining (+/++/+++): 78.6%;), and HCV-infection (mean score: 0.86; median score: 0.5; maximal score: 3; frequency of positive EpCAM staining (+/++/+++): 63.6%). Patients with AIH had an intermediate EpCAM staining (mean score: 0.72; median score: 0.5; maximal score: 3; frequency of positive EpCAM staining (+/++/+++): 55.6%;). Hepatocellular EpCAM expression was almost absent in patients with the chronic biliary diseases PBC (mean score: 0.13; median score: 0; maximal score: 0.5; frequency of positive EpCAM staining (+/++/+++): 25.0%;) and PSC (mean score: 0.04; median score: 0; maximal score: 0.5; frequency of positive EpCAM staining (+/++/+++): 7.7%;) ( FIG. 9 ; description of statistical variables is shown in the figure at the right box plot).
[0106] Conclusion. Tissue samples from patients with chronic liver disease like chronic hepatitis C virus (HCV) and hepatitis B virus (HBV) infection, chronic autoimmune hepatitis (AIH), chronic alcoholic liver disease (ALD) and hepatocellular carcinoma (HCC) were analyzed semi-quantitatively for EpCAM expression in correlation with the stage of liver fibrosis as well as histological and biochemical parameters of necroinflammatory activity. Hepatocytes, which are EpCAM-negative in normal adult liver, showed de novo EpCAM expression in many liver tissues from patients with chronic liver diseases. Hepatocellular EpCAM expression was highest in patients with necroinflammatory diseases (HCV and HBV hepatitis, AIH, ALD). Hepatocellular EpCAM expression correlated significantly with histological and biochemical parameters of inflammatory activity and the extent of fibrosis, which was particularly striking in patients with HBV infection. Furthermore, 14.3% of the HCCs showed EpCAM expression on tumor cells.
[0107] The results demonstrate that de novo expression of EpCAM occurs only in a fraction of hepatocellular carcinomas (HCCs), but frequently on hepatocytes in chronic necroinflammatory liver diseases. This expression positively correlates with disease activity and fibrosis. Specifically, a correlation of hepatocellular EpCAM neo-expression in chronic necroinflammatory liver disease and fibrosis and necroinflammatory activity has been demonstrated. These findings have implications for upcoming treatment options, such as monoclonal antibodies targeting EpCAM in malignant tumors, and may also apply to some HCCs. As a specific consequence, a fraction of HCCs may represent a valid target for EpCAM directed antibody therapy.
Example 5
Corroboration of Pharmacokinetic Predictions Using Patient Data Obtained in Phase II Study of “Anti-EpCAM”
[0108] It was desired to confirm the accuracy of the predictions based on pharmacokinetic modelling (themselves based on pharmacokinetic data obtained from the Phase I study of Anti-EpCAM, see Examples 1 and 2 hereinabove) using actual patient data obtained from a subsequent Phase II study in which Anti-EpCAM was administered according to the invention. This phase II study was an international, open-label, multicenter, randomized, phase II study with two parallel treatment groups. Patients participating in the Anti-EpCAM phase II study were randomized into two groups, the first of which receiving a low dose of Anti-EpCAM (2 mg/kg body weight) administered as explained below, and the second of which receiving a high dose of Anti-EpCAM (6 mg/kg body weight) administered as explained below. In the course of the Anti-EpCAM phase II study, each patient initially received three loading doses of Anti-EpCAM (each either 2 mg/kg body weight or 6 mg/kg body weight, depending on the patient group) spaced one week apart during a loading phase, followed by up to 23 subsequent maintenance doses of Anti-EpCAM (again, either 2 mg/kg body weight or 6 mg/kg body weight, depending on the patient group), wherein single maintenance doses were administered every second week.
[0109] According to the pharmacokinetic predictions based on Anti-EpCAM phase I study data, the serum trough level of the first patient group receiving the low dose of Anti-EpCAM would be expected to be on the order of 10 μg/ml (correlating the trough level shown in FIG. 7 ), whereas the serum trough level of the second patient group receiving the high dose of Anti-EpCAM would be expected to be on the order of 30 μg/ml (correlating with the trough level shown in FIG. 6 ).
[0110] The assay was carried out as follows. 96 well plates were coated with HD4A4 (anti-idiotype Antibody against Anti-EpCAM; 5 μg/ml in a volume of 100 ml) followed by a blocking and washing step. Calibration standards, quality control samples and samples of Anti-EpCAM were added (100 ml in an appropriate dilution) followed by a washing step. Anti-EpCAM bound by HD4A4 was detected with a biotinylated anti-human IgG, again followed by a washing step. Streptavidin was added (0.5 mg/ml in a volume of 100 μl), the 96 well plate was washed again and in a final step 180 μl of pNPP were added. The assay was stopped with 50 μl of 3 M NaOH and measured in an ELISA Reader at 405 and 490 nm. Dilution of low dose samples was performed in a relationship of 1:100. Dilution of high dose samples was performed in a relationship of 1:300. The results are shown in FIG. 10 .
[0111] FIG. 10 depicts as points the individual trough levels measured for one patient from the low-dosage group (patient number 401001; data points indicated by squares) and another patient from the high-dosage group (patient number 101002; data points indicated by diamonds). The average vertical level of the horizontal line connecting the data points from a respective patient represents the serum trough level observed for that patient. Accordingly, it can be seen that the horizontal line for the high-dose patient 101002 (diamond points) indicates a trough level concentration of Anti-EpCAM in good agreement with the predicted value of 30 μg/ml for this dose (compare horizontal line connecting predicted troughs of graph in FIG. 6 ). Likewise, the horizontal line for the low-dose patient 401001 (square points) indicates a trough level concentration of Anti-EpCAM in good agreement with the predicted value of 10 μg/ml for this dose (compare horizontal line connecting predicted troughs of graph in FIG. 7 ).
[0112] These data corroborate the accuracy of the trough level predictions by pharmacokinetic modelling based on data obtained during the Anti-EpCAM phase I study with actual patient data obtained during the Anti-EpCAM phase II study. As such, it can be concluded that the assumptions and results of the pharmacokinetic modelling were correct, and that the treatment regimen according to the invention has the effects and advantages elaborated hereinabove.
[0113] All of the compositions and methods disclosed and claimed herein can be made and executed without undue experimentation in light of the present disclosure. While the compositions and methods of this invention have been described in terms of preferred embodiments, it will be apparent to those of skill in the art that variations may be applied to the compositions and methods and in the steps or in the sequence of steps of the methods described herein without departing from the concept, spirit and scope of the invention. More specifically, it will be apparent that certain agents which are both chemically and physiologically related may be substituted for the agents described herein while the same or similar results would be achieved. All such similar substitutes and modifications apparent to those skilled in the art are deemed to be within the spirit, scope and concept of the invention as defined by the appended claims. | The invention relates inter alia to a method of treating tumorous disease in a human patient by administering to the patient a human immunoglobulin specifically binding to the human EpCAM antigen, the immunoglobulin exhibiting a serum half-life of at least 15 days, the method comprising the step of administering the immunoglobulin no more frequently than once every week, preferably no more frequently than once every two weeks. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of application Ser. No. 10/159,590, entitled Methods of Generating Gas in Well Fluids, filed on May 31, 2002, now U.S. Pat No. 6,715,553 which is hereby incorporated in its entirety by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to methods of chemically generating gas in aqueous fluids utilized in the drilling and completion of wells such as drilling fluids, spacer fluids and aqueous acid solutions.
2. Description of the Prior Art
Foamed aqueous fluids have heretofore been utilized in a number of oil and gas well applications. Typically, the aqueous fluids are foamed by combining mixtures of foaming and foam stabilizing surfactants with the fluids on the surface followed by injecting gas, typically nitrogen, into the fluids containing the foaming and foam stabilizing surfactants as the fluids are pumped to the well head and into the well bore. This process allows the final foamed fluid to have gas concentrations of 1% to 80% by volume of the fluid depending on the downhole pressure and temperature and the amount of gas injected at surface. The equipment and personnel required for storing the nitrogen in liquid or gaseous form and injecting it into well fluids is very elaborate and expensive. In addition, the equipment is frequently unavailable or cannot be easily transported to well sites due to their remote locations.
In-situ gas forming agents have been utilized heretofore in well cement compositions to prevent annular gas migration. For example, surfactant coated finely ground aluminum has been included in cement compositions to generate hydrogen gas in the compositions as they are being pumped down a well bore and after they are placed in the annulus between the walls of the well bore and casing or other pipe string therein. The presence of the gas in the cement compositions prevents formation fluids from entering the cement compositions as the cement compositions develop gel strength. That is, the development of gel strength and the cement hydration reaction that takes place reduces the ability of a cement composition column to transmit hydrostatic pressure. If the hydrostatic pressure of the cement composition column falls below the formation pore pressure before the cement composition has gained sufficient strength to prevent the entry of formation fluids into the well bore, the fluids enter the well bore and form channels in the cement composition column which remain after the cement composition column sets. The presence of the gas which is generated in the cement composition from the finely ground aluminum increases the volume of the cement composition such that the volume increase generated by the gas equals or slightly exceeds the cement composition volume reduction during the development of gel strength due to fluid loss and/or the cement hydration reaction. The increase in volume, typically less than 5%, and the compressibility produced in the cement composition by the gas allows the cement composition column to resist the entry of formation fluids into the well bore.
Other gas forming agents have also been added to well cement compositions to gasify the compositions. For example, U.S. Pat. No. 4,450,010 issued on May 22, 1984 to Burkhalter et al. discloses a well cementing method and gasified cements useful in carrying out the method. That is, U.S. Pat. No. 4,450,010 discloses a method of cementing in subterranean formations using a gasified cement composition which prevents formation fluids from entering the cement composition column formed in the annulus between the well bore and a pipe string therein. The cement composition includes a nitrogen gas generating material, an oxidizing agent and a reaction rate control material whereby a quantity of gas is generated in the cement composition to offset the shrinkage in the cement composition column as it develops gel strength and to provide compressibility thereto whereby the entry of formation fluids into the well bore is reduced or prevented.
A situation where the presence of gas would provide a distinct advantage involves problems associated with high fluid pressure buildup behind casing. Occasionally, aqueous drilling fluids, spacer fluids or both are left behind casing during the cementing phase of well construction. When the well is put on production, the formation temperature heats up the trapped drilling and/or spacer fluids causing severe high pressure buildups due to the incompressibility of the fluids which can cause damage to the casing. The presence of a compressible gas behind the casing in drilling fluids, spacer fluids and the like, either in the form of a gas pocket or foam would help sustain the temperature increases without severe pressure buildups.
Other applications where the presence of gas in aqueous drilling fluids, aqueous spacer fluids, aqueous acid solutions and the like would provide distinct advantages include drilling and well treating fluid hydrostatic pressure reduction to prevent formation fractures, drill cuttings removal, the displacement of drilling fluids in an eccentric annulus, hydrostatic fracture pressure control, fluid loss control and spent acid solution recovery.
SUMMARY OF THE INVENTION
The present invention relates to methods of chemically generating gas in aqueous fluids utilized in the drilling and completion of wells such as drilling fluids, spacer fluids and aqueous acid solutions.
In one embodiment, the present invention provides a method of preventing the formation of fractures in a subterranean formation during a drilling operation that comprises the steps of providing a lightweight drilling fluid that comprises an aqueous fluid and generated gas, the generated gas being generated by a reaction of a gas generating chemical in the aqueous fluid, the gas generating chemical being present in an amount of from about 0.1% to about 10% by weight of the aqueous fluid; and using the lightweight drilling fluid in the drilling operation to drill a well bore in the subterranean formation.
In one embodiment, the present invention provides a method of separating a first fluid and a second fluid in a subterranean formation that comprises the steps of providing a lightweight spacer fluid that comprises an aqueous fluid and generated gas, the generated gas being generated by a reaction of a gas generating chemical in the aqueous fluid, the gas generating chemical being present in an amount of from about 0.1% to about 10% by weight of the aqueous fluid; providing a first fluid and a second fluid, the second fluid to be introduced to the subterranean formation after the first fluid; placing the first fluid into the subterranean formation; placing the lightweight spacer fluid into the subterranean formation to substantially separate the first fluid from the second fluid; and placing the second fluid into the subterranean formation.
In another embodiment, the present invention provides a method of forming a lightweight well treatment fluid that comprises a gas for use in a subterranean formation that comprises the steps of mixing an aqueous fluid, a surfactant, and a gas generating chemical, the gas generating chemical being present in an amount of from about 0.1% to about 10% by weight of a water component in the aqueous fluid, to form a well treatment fluid; and allowing the gas generating chemical to react so as to generate a gas in the well treatment fluid to form a lightweight well treatment fluid.
In another embodiment, the present invention provides a method of enhancing the permeability of a subterranean zone that comprises the steps of allowing a gas generating chemical to react in an aqueous fluid to generate generated gas; adding the generated gas to an aqueous acidic well treatment fluid to produce a foamed aqueous acidic well treatment fluid; and using the foamed aqueous acidic well treatment fluid in a treatment to enhance the permeability of a subterranean zone.
In another embodiment, the present invention provides a lightweight drilling fluid that comprises an aqueous fluid and a gas generated by a reaction of a gas generating chemical in the aqueous fluid, the gas generating chemical being present in an amount of from about 0.1% to about 10% by weight of the aqueous fluid.
In another embodiment, the present invention provides a lightweight spacer fluid that comprises an aqueous fluid and a gas generated by a reaction of a gas generating chemical in the aqueous fluid, the gas generating chemical being present in an amount of from about 0.1% to about 10% by weight of the aqueous fluid.
In another embodiment, the present invention provides a foamed aqueous acidic well treatment fluid that comprises an acid component and generated gas, the generated gas being a product of a reaction of a gas generating chemical in an aqueous fluid.
In another embodiment, the present invention provides a method of making a foamed aqueous acidic well treatment fluid that comprises the steps of reacting a gas generating chemical in an aqueous fluid to generate some generated gas; and incorporating the generated gas into an aqueous acidic well treatment fluid to produce a foamed aqueous acidic well treatment fluid.
In one embodiment, the present invention provides a method of making a foamed well fluid that comprises a gas that comprises the steps of combining an aqueous fluid, a surfactant, and a gas generating chemical, the gas generating chemical being present in an amount in the range of from about 0.1% to 100% of a water component in the aqueous well fluid; and allowing the gas generating chemical to react so that gas is generated in the aqueous fluid to form a foamed well fluid. In another aspect, the present invention provides a foamed well fluid made by the methods provided herein.
The features and advantages of the present invention will be readily apparent to those skilled in the art upon a reading of the description of the preferred embodiments, which follows.
DESCRIPTION OF PREFERRED EMBODIMENTS
The present invention provides improved methods of generating gas in and foaming aqueous well fluids such as aqueous drilling fluids, aqueous spacer fluids, aqueous acid solutions and the like.
Aqueous well drilling fluids are generally solids containing water based gels which can include a weighting material. When a lightweight aqueous drilling fluid is required in order to prevent the hydrostatic pressure of the drilling fluid from creating fractures in weak formations, the drilling fluid can be foamed in accordance with this invention.
Aqueous spacer fluids are often used in oil and gas wells to facilitate improved displacement efficiency when pumping new fluids into the well bore. The spacer fluids are typically placed between one or more fluids contained within or to be pumped within the well bore. Examples include placing spacer fluids between a hydraulic cement slurry and a drilling fluid, between different drilling fluids during drilling fluid change outs or between a drilling fluid and a completion brine. Spacers are also used to enhance solids removal during drilling operations, to enhance displacement efficiency and to physically separate chemically incompatible fluids.
Most spacer fluids are comprised of water, a viscosity and fluid loss control additive, a weighting material and a surfactant. The weighting material included in the spacer fluid is to increase its density for well control and increase the buoyancy effect of the spacer fluid on the gelled drilling fluid and filter cake adhered to the walls of the well bore. Viscosity additives are intended to produce Theological properties which provide suspended particle stability and fluid loss control to the spacer fluid. When a surfactant is included in the spacer fluid it is intended to enhance the chemical compatibility of the spacer fluid with the other fluids and to water-wet surfaces for an improved cement bond and better removal of well bore solids. In some applications, it is desirable to foam spacer fluids to improve fluid displacement and for reducing the hydrostatic pressure of the fluid column in the well bore.
In accordance with the methods of this invention, one or more gas generating chemicals are combined with an aqueous well fluid on the surface. At approximately the same time, a mixture of foaming and foam stabilizing surfactants and when needed, an activator for said one or more gas generating chemicals selected from a base or buffer for increasing the pH of the well fluid to in the range of from about 10 to about 14 or one or more oxidizing chemicals with or without one or more rate control agents are combined with the aqueous well fluid so that the gas generating chemicals react with the alkaline well fluid or the oxidizing chemicals and gas and foam are formed in the well fluid while it is being pumped. Thereafter, the well fluid is pumped into a well bore.
When the methods of this invention are utilized to foam aqueous well fluids that are already alkaline, i.e., have a pH in the range of from about 10 to about 14, the activators described above are not needed. That is, the gas generating chemicals react with the alkaline aqueous well fluids upon mixing therewith.
The gas generating chemicals useful in accordance with this invention primarily generate nitrogen along with small amounts of ammonia depending on the chemical structure and the activating chemical or chemicals. When the gas generating chemical molecule contains amide groups, additional ammonia, carbon dioxide (an acidic gas), and carbon monoxide may be produced. The gas generating chemicals are generally solid materials that liberate gas or gases on their own when they are heated to a temperature in the range of from about 200° F. to about 500° F. without requiring alkaline conditions or oxidizing chemicals. In order to cause the gas generating chemicals to generate gases at a temperature below about 200° F., e.g., at ambient temperature, an alkaline chemical or an oxidizing chemical with or without a rate control agent can be combined with the aqueous well fluid containing the one or more gas generating chemicals and foaming and foam stabilizing surfactants. Depending on the structure of the gas generating chemical, it may dissolve in the aqueous well fluid or it may have to be used as a dispersion.
Examples of gas generating chemicals which can be utilized in accordance with the methods of the present invention include, but are not limited to, chemicals containing hydrazine or azo groups such as hydrazine, azodicarbonamide, azobis(isobutyronitrile), p-toluene sulfonyl hydrazide, p-toluene sulfonyl semicarbazide, carbohydrazide, p-p′-oxybis(benzenesulfonyl hydrazide), and mixtures thereof. Other examples of nitrogen generating chemicals include, but are not limited to, ammonium salts of organic or inorganic acids, hydroxylamide sulfate, carbamide and mixtures thereof. Of the gas generating chemicals which can be used, azodicarbonamide and carbohydrazide are preferred. The gas generating chemical or chemicals utilized are combined with the aqueous well fluid in a general amount, depending on the amount of gas desired under downhole conditions, in the range of from about 0.1% to about 10% by weight of water in the aqueous well fluid, more preferably in an amount in the range of from about 0.3% to about 8% and most preferably about 4%.
The generation of gas from the gas generating chemicals depends on the structure of the gas generating chemicals. When the chemical contains an azo group containing two nitrogens connected by a double bond as in azodicarbonamide, the gas generation is caused either thermally or by reaction with alkaline reagents which by reacting with the azocarbonamide generate ammonia gas, carbon dioxide and release the doubly charged diimide group. The diimide dianion being chemically unstable decomposes to nitrogen gas.
The gas generating chemicals containing hydrazide groups in which the two nitrogen atoms are connected by a single bond as well as connected to one or two hydrogens produce gas upon reaction with oxidizing chemicals. It is believed that the oxidizing agent oxidizes the hydrazide group to azo structure. Occasionally, additional activator chemicals may be needed to increase the rate of gas production.
While various activators can be utilized to make the aqueous well fluid to be foamed alkaline, a preferred activator is a base such as alkali metal hydroxides, alkaline earth metal hydroxides or alkaline metal salts of silicates present in the well fluid in an amount sufficient to maintain the pH of the fluid in the 10 to 14 range during the gas production phase. A buffer composition which can maintain the pH in the desired range can also be used. Examples of suitable buffer compositions include mixtures of potassium phosphate and potassium monohydrogenphosphate or sodium carbonate and sodium bicarbonate.
Examples of the oxidizing chemical activators which can be used include, but are not limited to, alkaline and alkaline earth metal salts of peroxide, persulfate, perborate, chlorite, chlorate, iodate, bromate, chloroaurate, arsenate, antimonite and molybate anions. Specific examples of the oxidizing agents include ammonium persulfate, sodium persulfate, potassium persulfate, sodium chlorite, sodium chlorate, hydrogen peroxide, sodium perborate and sodium peroxy carbonate. Other examples of oxidizing chemicals which can be used in the present invention are disclosed in U.S. Pat. No. 5,962,808 issued to Landstrom on Oct. 5, 1999 which is incorporated herein by reference thereto. Of the oxidizing chemicals which can be used, sodium persulfate and sodium chlorite are the most preferred. When used, one or more oxidizing chemicals are included in the well fluid in an amount in the range of from about 200% to about 1500% by weight of the gas generating chemical or chemicals therein, more preferably in an amount in the range of from about 400% to about 1200% by weight of the gas generating chemical or chemicals. The oxidizing chemical or chemicals used and their amounts are selected for their ability to cause the gas generating chemical or chemicals to generate gas at a particular temperature or range of temperatures. The temperatures at which various oxidizing chemicals cause a particular gas generating chemical to produce gas can be readily determined in the laboratory.
As mentioned above, a gas production rate enhancing agent can be used when rapid gas production is desired. Examples of such rate enhancing agents include, but are not limited to, copper salts such as copper sulfate and iron salts including ferric sulfate or ferric nitrate. When used, the gas production rate enhancing agent is included in the well fluid in an amount in the range of from about 5% to about 25% by weight of the gas generating chemical or chemicals therein.
The mixture of foaming and foam stabilizing surfactants is combined with the aqueous well fluid to facilitate the formation and stabilization of foam in the well fluid produced by the liberation of gas therein. An example of such a mixture of foaming and foam stabilizing surfactants which is preferred for use in accordance with this invention is comprised of a mixture of an ethoxylated alcohol ether sulfate surfactant, an alkyl or alkene amidopropylbetaine surfactant and an alkyl or alkene amidopropyldimethylamine oxide surfactant. Such a surfactant mixture is described in U.S. Pat. No. 6,063,738 issued to Chatterji et al. on May 16, 2000 which is incorporated herein by reference thereto. The mixture of foaming and foam stabilizing surfactants is present in said well fluid in an amount in the range of from about 0.5% to about 5% by weight of water in the aqueous well fluid.
Thus, an improved method of this invention for generating gas in and foaming an aqueous drilling fluid, an aqueous spacer fluid or other similar aqueous well fluid pumped into a subterranean zone penetrated by a well bore is comprised of the steps of: combining with the aqueous well fluid one or more gas generating chemicals, a mixture of foaming and foam stabilizing surfactants and when needed, an activator for the one or more gas generating chemicals selected from the group consisting of a base or buffer for increasing the pH of the well fluid to in the alkaline range of from about 10 to about 14 and an oxidizing agent so that the gas generating chemicals react with the alkaline well fluid or the oxidizing agent and gas and foam are formed in the well fluid while it is being pumped; and pumping the aqueous well fluid into the well bore and the subterranean zone.
As mentioned above the well fluid can optionally include a rate enhancing chemical to increase the rate of gas production from the one or more gas generating chemicals at a selected temperature.
Another preferred improved method of this invention for generating gas in and foaming an aqueous well fluid such as an aqueous drilling fluid, an aqueous spacer fluid and the like which is pumped into a subterranean zone penetrated by a well bore is comprised of the steps of: combining with the aqueous well fluid a gas generating chemical comprised of azodicarbonamide in an amount in the range of from about 0.3% to about 8% by weight of water in the aqueous well fluid, a mixture of foaming and foam stabilizing surfactants present in an amount in the range of from about 0.5% to about 5% by weight of water in the aqueous well fluid and an activator for the gas generating chemical selected from the group consisting of a base or buffer in an amount sufficient to increase the pH of the well fluid to in the range of from about 10 to about 14 so that the gas generating chemical reacts with the alkaline well fluid and gas and foam is formed in the well fluid while it is being pumped; and pumping the well fluid into the well bore and the subterranean zone.
Yet another preferred improved method of this invention for generating gas in and foaming an aqueous well fluid such as an aqueous drilling fluid, an aqueous spacer fluid and the like which is pumped into a subterranean zone penetrated by a well bore is comprised of the steps of: combining with the aqueous well fluid a gas generating chemical comprised of azodicarbonamide in an amount in the range of from about 0.3% to about 8% by weight of water in the aqueous well fluid, a mixture of foaming and foam stabilizing surfactants present in an amount in the range of from about 0.5% to about 5% by weight of water in the aqueous well fluid and an activator for the gas generating chemical comprised of an oxidizing chemical so that the gas generating chemical reacts with the oxidizing chemical and gas and foam are formed in the aqueous well fluid while it is being pumped; and pumping the aqueous well fluid formed in step (a) into the well bore and the subterranean zone.
In certain circumstances, it is desirable to foam an aqueous acid solution which is introduced into a subterranean zone to increase the hydrocarbon permeability of the zone. The presence of the gas in the foamed acid solution assists in the recovery of the spent acid from the subterranean zone.
In accordance with the present invention, an aqueous solution or dispersion of one or more gas generating chemicals is combined with an activator for the gas generating chemicals selected from the group consisting of a base or buffer for increasing the pH of the aqueous solution or dispersion to in the alkaline range of from about 10 to about 14 and an oxidizing chemical so that the gas generating chemicals react with the alkaline solution or dispersion or the oxidizing chemical on the surface to generate gas. The gas is then combined with the aqueous acid solution in an amount sufficient to foam the aqueous acid solution as the aqueous acid solution is pumped into the well bore and into the subterranean zone to be acidized whereby the aqueous acid solution is foamed.
One or more of the gas generating chemicals described above can be utilized to form the aqueous solution or dispersion of gas generating chemicals. The water utilized can be any type of water so long as it does not contain components which adversely react with the gas generating chemicals. The activator can be a base or buffer as described above or one or more of the oxidizing chemicals described above. Generally, the gas generating chemical or chemicals used are included in the solution or dispersion in an amount in the range of from about 10% to about 100% by weight of water therein. As mentioned, when the activator is a base or buffer it is added to the aqueous solution or dispersion in an amount sufficient to raise the pH of the solution or dispersion to in the range of from 10 to about 14. One or more of the oxidizing chemical activators described above can be utilized instead of or in addition to the base or buffer in an amount in the range of from about 400% to about 1200% by weight of the gas generating chemical or chemicals in the solution or dispersion.
When a base or buffer activator or an oxidizing chemical activator, or both, are combined with the aqueous solution or dispersion of one or more gas generating chemicals, the gas evolved from the mixture is collected and combined with the aqueous acid solution which can include a mixture of foaming and foam stabilizing surfactants such as linear alcohol (C 10 –C 13 ) ethoxylates (e.g., 10–20 moles ethylene oxide), betaines (e.g., cocoamidopropyl betaine) and nonylphenol ethoxylate (e.g., 2 moles ethylene oxide) in an amount in the range of from about 1% to 5% by weight of water in the combined acid solution.
The aqueous acid solution utilized can include, but is not limited to hydrochloric acid, hydrofluoric acid, fluoroboric acid and mixtures thereof. The aqueous acid solution can also include one or more organic acids including, but not limited to, formic acid, acetic acid, citric acid, lactic acid, thioglycolic acid and glycolic acid. Generally, the inorganic acid is present in the aqueous acid solution in an amount in the range of from about 5% to about 30% by weight of the aqueous acid solution. When used, the organic acid can be present in an amount up to about 10% by weight of the aqueous acid solution.
An improved method of this invention for chemically generating gas and foaming an aqueous acid solution which is introduced into a subterranean zone penetrated by a well bore to increase the hydrocarbon permeability of the zone, the presence of the gas in the foamed acid solution assisting in the recovery of the spent acid from the subterranean zone, comprising the steps of: (a) combining an aqueous solution or dispersion of one or more gas generating chemicals with an activator for the gas generating chemicals selected from the group consisting of a base or buffer for increasing the pH of the aqueous solution or dispersion to in the alkaline range of from about 10 to about 14 and an oxidizing chemical so that the gas generating chemicals react with the alkaline well fluid or the oxidizing chemical on the surface to generate gas; and (b) combining the gas with the aqueous acid solution in an amount sufficient to foam the aqueous acid solution as the aqueous acid solution is pumped into the well bore and the subterranean zone to be acidized whereby the aqueous acid solution is foamed.
In order to further illustrate the methods of the present invention, the following examples are given. In no way should the following examples be read to limit or define the scopes of the invention.
EXAMPLE 1
A spacer fluid was prepared as described in U.S. Pat. No. 5,789,352 issued to Carpenter et al. on Aug. 14, 1998 which is incorporated herein by reference thereto. An aqueous mixture of foaming and foam stabilizer surfactants comprising alcohol ether sulfate, cocoamidopropyl betaine and an amine oxide in water was stirred by hand into the spacer fluid in an amount of about 1.83% by weight of water in the spacer fluid. The density of the spacer fluid was 16.35 pounds per gallon and the pH of the fluid was 9.1. In a graduated cylinder containing 20 ml of the spacer fluid, azodicarbonamide was added in an amount of 2% by weight of water present in the spacer fluid. The pH was adjusted to 12.2 by the addition of a few drops of 17% sodium hydroxide solution. As the resulting reaction progressed, the pH decreased. Periodically, the pH was adjusted to 12.2 by additional sodium hydroxide solution. The final fluid volume was 42 ml and final density was 7.73 pounds per gallon. The percent nitrogen gas present in the fluid was 50% by volume.
An identical experiment to the above was performed by substituting toluene sulfonyl hydrazide for the azodicarbonamide in an amount of 3% by weight of water in the spacer fluid. Additionally, 2.5 ml of 37% sodium persulfate solution in water was added in 0.5 ml portions. The pH was adjusted to 11.0 periodically as necessary. At the end of the experiment, the volume of the foamed fluid was 42 ml (density—7.84 pounds per gallon; % nitrogen gas in the fluid—48% by volume).
Another experiment identical to the preceding experiment was conducted by substituting 37% by volume sodium chlorite solution in water for the 37% by volume sodium persulfate solution. The initial pH was adjusted to 10.7. No additional pH adjustment was found necessary during the course of the addition of the sodium chlorite solution. The final volume of 48 ml (density—7.28 pounds per gallon; % nitrogen gas—54% by volume) was reached much quicker (10 min vs. 2 ills) than in the preceding case.
Another experiment identical to the preceding experiment was performed by replacing toluene sulfonyl hydrazide with 1% carbohydrazide by weight of water. A pH adjustment was not necessary since the pH did not change during the course of the reaction. The final volume at the end of the reaction period, was 70 ml (density—4.9 pounds per gallon; % nitrogen gas—68% by volume).
Another experiment identical to the preceding experiment was performed by replacing the sodium chlorite with an equal volume of 37% sodium persulfate solution. The final volume was 40 ml (density—8.75 pounds per gallon; % nitrogen gas—45% by volume). The above experiments clearly demonstrate that spacer fluid compositions used in oil well operations can be foamed by generating nitrogen gas in-situ.
EXAMPLE 2
A test was conducted using Halliburton's UCA (Ultrasonic Cement Analyzer) equipment. About 110 ml of a drilling fluid was placed in the UCA cell with a volume capacity of 220 ml. The cell was pressurized to 2000 psi and placed in the UCA heating jacket. The temperature was brought to 80° F.
A sample of the spacer fluid described in Example 1 including the mixture of the foaming and foam stabilizing surfactants was placed in a stirring autoclave and heated to 80° F. A pressure of 2000 psi was applied and the sample of spacer fluid was foamed to contain specified volume of air. The foamed spacer fluid was transferred under pressure into the UCA cell. The UCA was programmed to heat up to 200° F. over a specified period. The resulting pressure increases were recorded at 140° F., 180° F. and 200° F. The test was repeated with different drilling fluids and spacer fluids containing different volumes of air and finally with tap water. The results are presented in the Table below.
TABLE
Drilling and Spacer Fluids Tested and Resulting Pressures
Fluid Sample
80° F.
140° F.
180° F.
200° F.
100% “NOVA Plus ™” 1
2000 psi
5400 psi
9200 psi
10,000 psi
50% “NOVA Plus ™” and 50% - Spacer with 10% air
2000 psi
2100 psi
2400 psi
2600 psi
50% “NOVA Plus ™” and 50% - Spacer with 20% air
2000 psi
2100 psi
2300 psi
2400 psi
50% “NOVA Plus ™” and 50% - Spacer with 40% air
2000 psi
2000 psi
2100 psi
2200 psi
100% “Cal-Drill Mud ™” 2
2000 psi
6500 psi
10,000 psi
11,400 psi
50% “Cal-Drill Mud ™” and 50% - Spacer with 10% air
2000 psi
3000 psi
3700 psi
3800 psi
50% “Cal-Drill Mud ™” and 50% - Spacer with 20% air
2000 psi
2500 psi
2700 psi
2900 psi
50% “Cal-Drill Mud ™” and 50% - Spacer with 40% air
2000 psi
2100 psi
2200 psi
2250 psi
65% Oil/ester based drilling fluid and 35% Spacer with 10%
2000 psi
2200 psi
2300 psi
2500 psi
in-situ generated nitrogen
Tap Water
2000 psi
4800 psi
8200 psi
10,300 psi
1 According to the information provided by the supplier, MI Fluids of Houston, Texas, the drilling fluid contained C16–C18 Internal Olefins (80%), water (5–40%), calcium chloride (15–30%), viscosifier (3–10 pounds per barrel), emulsifier (6–8 pounds per barrel), wetting agent (2–4 pounds per barrel), rheology modifier (1–3 pounds per barrel) and lime 4 to 8 pounds per barrel.
2 According to the information provided by the supplier, MI Fluids of Houston, Texas, the drilling fluid contained calcium chloride brine (9.6 pounds per gallon), a polymer (D-I50, 2 pounds per barrel), attapulgite (5 pounds per barrel), biopolymer (1 pound per barrel) and defoamer (0.5 pounds per barrel).
The results clearly show that when a gas is present in a fluid system, for example, as would be in the case of spacer and drilling fluid left behind a casing in a completed oil well, the pressure increases exerted on the pipe due to heating of the fluids by the formation are less when the fluids contain gas than when there is no gas present. The prevention of excessive pressure buildup behind a casing in a well prevents well blowouts and casing collapses.
EXAMPLE 3
A representative water-based drilling fluid was prepared by mixing with shear in a Waring blender bentonite clay (10 pounds per barrel), mixed metal silicate available from Baroid Corporation under the trade name “RV-310™” (0.75 pounds per barrel), carboxymethylcellulose (4 pounds per barrel), barium sulfate in tap water (90 pounds per barrel), and a foaming and foam stabilizing surfactant mixture comprising alcohol ether sulfate, cocoamidopropyl betaine and an amine oxide in water was stirred by hand into the drilling fluid (3.5% by weight of water in the drilling fluid). The density of the resulting drilling fluid was 9.72 pounds per gallon, and the pH of the fluid was 11.94.
In a graduated cylinder containing 20 ml of the drilling fluid solid azodicarbonamide was added (0.5% by weight of water) with gentle stirring. In 90 minutes, the volume increased to 28 ml (density—6.91 pounds per gallon).
Another experiment identical to the preceding experiment was performed except that 1% azodicarbonamide by weight of water was added to the drilling fluid. In 90 minutes, the volume increase was same as in the preceding experiment. The pH was not adjusted in either of the above experiments.
Another experiment identical to the preceding was performed except that the azodicarbonamide was replaced with carbohydrazide (0.5% by weight of water). To this mixture, 1 ml of 37% sodium chlorite solution was added with stirring. In 15 minutes, the fluid volume increased to 30 ml (density—6.45 pounds per gallon).
The above results show that drilling fluids can be foamed by chemically generating nitrogen gas in-situ.
Thus, the present invention is well adapted to carry out the objects and attain the ends and advantages mentioned as well as those which are inherent therein. While numerous changes can be made by those skilled in the art, such changes are encompassed within the spirit of this invention as defined by the appended claims. | The present invention relates to methods of chemically generating gas in aqueous fluids utilized in the drilling and completion of wells such as drilling fluids, spacer fluids, and aqueous acid solutions. In one embodiment, the invention provides a method of preventing the formation of fractures in a subterranean formation during a drilling operation. In other embodiments, the present invention provides methods of separating a first fluid and a second fluid in a subterranean formation; methods of forming lightweight well treatment fluids; methods of enhancing the permeability of a subterranean zone; lightweight drilling fluids; lightweight spacer fluids; foamed aqueous acidic well treatment fluids; and methods of making foamed aqueous and aqueous acidic well treatment fluids. | 2 |
FIELD OF THE INVENTION
The present invention relates to halogenated butyl elastomers, in particular bromobutyl elastomers. Further, the present invention relates to a process for preparing a filled halobutyl elastomer.
BACKGROUND OF THE INVENTION
It is known that reinforcing fillers such as carbon black and silica greatly improve the strength and fatigue properties of elastomeric compounds. It is also known that chemical interaction occurs between the elastomer and the filler. For example, good interaction between carbon black and highly unsaturated elastomers such as polybutadiene (BR) and styrene butadiene copolymers (SBR) occurs because of the large number of carbon-carbon double bonds present in these copolymers. Butyl elastomers may have only one tenth, or fewer, of the carbon-carbon double bonds found in BR or SBR, and compounds made from butyl elastomers are known to interact poorly with carbon black. For example, a compound prepared by mixing carbon black with a combination of BR and butyl elastomers results in domains of BR, which contain most of the carbon black, and butyl domains which contain very little carbon black. It is also known that butyl compounds have poor abrasion resistance.
Co-pending U.S. application Ser. No. 09/742,797, published as US-2001-0009948-A1 on Jul. 26, 2001, shows that it is possible to produce filled butyl elastomer compositions with much improved properties by combining halobutyl elastomers with silica and specific silanes. These silanes act as dispersing and bonding agents between the halogenated butyl elastomer and the filler.
SUMMARY OF THE INVENTION
The present invention provides a process for preparing compositions containing halobutyl elastomers in which there is enhanced interaction between the elastomer and a filler, especially a mineral filler or carbon black. The invention also provides filled halobutyl elastomer compositions, which have improved properties when, compared to known carbon black-filled halobutyl elastomeric compositions. In particular it provides a means to produce such filled compositions without the evolution of alcohol, and at significantly reduced cost, compared to processes known in the art.
Surprisingly, it has been discovered that certain organic compounds containing at least one basic nitrogen-containing group and at least one hydroxyl group enhance the interaction of halobutyl elastomers with mineral fillers and carbon black, resulting in improved compound properties such as tensile strength and abrasion (DIN). Of particular interest are compounds containing primary amine and hydroxyl groups such as ethanolamine. These organic compounds are believed to disperse and bond the filler to the halogenated elastomers.
Accordingly, the present invention provides a process which comprises mixing a halobutyl elastomer with a filler, especially a mineral filler or carbon-black, in the presence of an additive which is an organic compound having at least one hydroxyl group and at least one basic nitrogen-containing group, and curing the resulting filled halobutyl elastomer. The resulting composition, having improved properties, forms another aspect of the invention.
The halobutyl elastomer that is admixed with the filler and the silane may be a mixture with another elastomer or elastomeric compound. The halobutyl elastomer should constitute more than 5% of any such mixture. Preferably the halobutyl elastomer should constitute at least 10% of any such mixture. In some cases it is preferred not to use mixtures but to use the halobutyl elastomer as the sole elastomer. If mixtures are used, then the other elastomer may be, for example, natural rubber, polybutadiene, styrene-butadiene or poly-chloroprene or an elastomer compound containing one or more of these elastomers.
The filled halobutyl elastomer can be cured to obtain a product, which has improved properties, for instance in abrasion resistance, rolling resistance and traction. Curing can be effected with sulfur. The preferred amount of sulfur is in the range of from 0.25 to 2.1 parts by weight per hundred parts of rubber. An activator, for example zinc oxide, may also be used, in an amount in the range of from 5 parts to 2 parts by weight. Other ingredients, for instance stearic acid, antioxidants, or accelerators may also be added to the elastomer prior to curing. Sulfur curing is then effected in known manner. See, for instance, chapter 2, “The Compounding and Vulcanization of Rubber”, of “Rubber Technology”, 3 rd edition, published by Chapman & Hall, 1995, the disclosure of which is incorporated by reference.
Other curatives known to cure halobutyl elastomers may also be used. A number of compounds are known to cure BIIR, for example, such as bis dieneophiles (for example HVA2) phenolic resins, amines, amino-acids, peroxides, zinc oxide and the like. Combinations of the aforementioned curatives may also be used.
The filled halobutyl elastomer of the present invention can be admixed with other elastomers or elastomeric compounds before it is subjected to the curing with sulfur or other known curatives. This is discussed in more detail below.
DETAILED DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a plot of the stress strain data for compositions containing BIIR, silica and an additive.
FIG. 2 illustrates a plot of the stress strain data for mono, di, and tri-ethanolamine in a compound containing BIIR and silica.
FIG. 3 illustrates the effect of the amino-alcohols on the stress at a given strain level.
FIG. 4 illustrates the advantages in scorch safety between N,N-dimethylethanolamine and ethanolamine.
DETAILED DESCRIPTION OF THE INVENTION
The phrase “halobutyl elastomer(s)” as used herein refers to a chlorinated or brominated butyl elastomer. Brominated butyl elastomers are preferred, and the invention is illustrated, by way of example, with reference to such bromobutyl elastomers. It should be understood, however, that the invention extends to the use of chlorinated butyl elastomers.
Halobutyl elastomers suitable for use in the present invention include, but are not limited to, brominated butyl elastomers. Such elastomers may be obtained by bromination of butyl rubber (which is a copolymer of isobutylene and a co-monomer that is usually a C 4 to C 6 conjugated diolefin, preferably isoprene). Co-monomers other than conjugated diolefins can be used, however, and mention is made of alkyl-substituted vinyl aromatic co-monomers such as C 1 -C 4 -alkyl substituted styrene. An example of such an elastomer which is commercially available is brominated isobutylene methylstyrene copolymer (BIMS) in which the co-monomer is p-methylstyrene.
Brominated butyl elastomer typically contains in the range of from 0.1 to 5 weight percent of isoprene and in the range of from 95 to 99.9 weight percent of isobutylene (based upon the hydrocarbon content of the polymer) and in the range of from 0.1 to 5 weight percent bromine (based upon the bromobutyl polymer). A typical bromobutyl polymer has a molecular weight, expressed as the Mooney viscosity (ML 1+8 at 125° C.), of from 28 to 55. Such brominated butyl elastomer can be prepared by means known in the art or are available commercially, e.g. as Bayer Bromobutyl® 2030 from Bayer Inc., Canada, which is an isobutene-isoprene copolymer with a ML 32±4 and a bromine content of 2 wt. %.
For use in the present invention the brominated butyl elastomer preferably contains in the range of from 1 to 2 weight percent of isoprene and in the range of from 98 to 99 weight percent of isobutylene (based upon the hydrocarbon content of the polymer) and in the range of from 0.5 to 2.5 weight percent, preferably in the range of from 0.75 to 2.3 weight percent, of bromine (based upon the brominated butyl polymer).
A stabilizer may be added to the brominated butyl elastomer. Suitable stabilizers include calcium stearate and epoxidized soybean oil, preferably used in an amount in the range of from 0.4 to 5 parts by weight per 100 parts by weight of the brominated butyl rubber.
Examples of suitable brominated butyl elastomers include Bayer Bromobutyl® 2030, Bayer Bromobutyl® 2040 (BB2040), and Bayer Bromobutyl® X2 commercially available from Bayer. Bayer BB2040 has a Mooney viscosity (RPML 1+8@125° C.) of 39±4, a bromine content of 2.0±0.3 wt % and an approximate molecular weight of 500,000 grams per mole.
The brominated butyl elastomer used in the process of this invention may also be a graft copolymer of a brominated butyl rubber and a polymer based upon a conjugated diolefin monomer. PCT Application NO. PCT/CA00/00866, published as WO 01/09225 A1 on Feb. 8, 2001, is directed towards a process for preparing such graft copolymers by mixing solid brominated butyl rubber with a solid polymer based on a conjugated diolefin monomer which also includes some C—S—(S) n —C bonds, where n is an integer from 1 to 7, the mixing being carried out at a temperature greater than 50° C. and for a time sufficient to cause grafting. The disclosure of this application is incorporated herein by reference. The bromobutyl elastomer of the graft copolymer can be any of those described above. The conjugated diolefins that can be incorporated in the graft copolymer generally have the structural formula
wherein R is a hydrogen atom or an alkyl group containing in the range of from 1 to 8 carbon atoms and wherein R 1 and R 11 can be the same or different and are selected from the group consisting of hydrogen atoms and alkyl groups containing in the range of from 1 to 4 carbon atoms. Some representative non-limiting examples of suitable conjugated diolefins include 1,3-butadiene, isoprene, 2-methyl-1,3-pentadiene, 4-butyl-1,3-pentadiene, 2,3-dimethyl-1,3-pentadiene 1,3-hexadiene, 1,3-octadiene, 2,3-dibutyl-1,3-pentadiene, 2-ethyl-1,3-pentadiene, 2-ethyl-1,3-butadiene and the like. Conjugated diolefin monomers containing in the range of from 4 to 8 carbon atoms are preferred, 1,3-butadiene and isoprene being especially preferred.
The polymer based on a conjugated diene monomer can be a homopolymer, or a copolymer of two or more conjugated diene monomers, or a copolymer with a vinyl aromatic monomer.
The vinyl aromatic monomers, which can optionally be used, are selected so as to be copolymerizable with the conjugated diolefin monomers being employed. Generally, any vinyl aromatic monomer, which is known to polymerize with organo-alkali metal initiators, can be used. Such vinyl aromatic monomers usually contain in the range of from 8 to 20 carbon atoms, preferably in the range of from 8 to 14 carbon atoms. Suitable vinyl aromatic monomers which can be so copolymerized include styrene, alpha-methyl styrene, various alkyl styrenes including p-methylstyrene, p-methoxy styrene, 1-vinylnaphthalene, 2-vinyl naphthalene, 4-vinyl toluene and the like. Styrene is preferred for copolymerization with 1,3-butadiene alone or for terpolymerization with both 1,3-butadiene and isoprene.
The filler is composed of particles of carbon-black or a mineral, and examples include silica, silicates, clay (such as bentonite), gypsum, alumina, titanium dioxide, talc and the like, as well as mixtures thereof. The mineral particles have hydroxyl groups on their surface (in significantly higher concentrations than that found for carbon-black), rendering them hydrophilic and oleophobic. This exacerbates the difficulty of achieving good interaction between the mineral filler particles and the butyl elastomer. Furthermore, the low levels of unsaturation found in butyl elastomers exacerbates the difficulty in achieving good interaction between this class of elastomers and carbon-black. For many purposes, the preferred mineral is silica, especially silica prepared by the carbon dioxide precipitation of sodium silicate.
Dried amorphous silica particles suitable for use in accordance with the invention have a mean agglomerate particle size between 1 and 100 microns, preferably between 10 and 50 microns and most preferably between 10 and 25 microns. It is preferred that less than 10 percent by volume of the agglomerate particles are below 5 microns or over 50 microns in size. A suitable amorphous dried silica moreover has a BET surface area, measured in accordance with DIN (Deutsche Industrie Norm) 66131, of between 50 and 450 square meters per gram and a DBP absorption, as measured in accordance with DIN 53601, of between 150 and 400 grams per 100 grams of silica, and a drying loss, as measured according to DIN ISO 787/11, of from 0 to 10 percent by weight. Suitable silica fillers are available under the trademarks HiSil 210, HiSil 233 and HiSil 243 from PPG Industries Inc. Also suitable are Vulkasil S and Vulkasil N, from Bayer AG.
Examples of carbon-blacks include carbon-blacks prepared by the lamp black, furnace black or gas black process and have BET specific surface areas of 20 to 200 m 2 /g, e.g. SAF, ISAF, HAF, SRF, FEF or GPF carbon-blacks.
The additive contains at least one hydroxyl group and at least one group containing a basic nitrogen atom. These groups possess the ability to (without being bound to any particular theory) react with the filler or with the active halogen in a halogenated butyl elastomer (for example with the active bromine atom in a brominated butyl elastomer). Functional groups containing —OH may be, for example, alcohols or carboxylic acids. Functional groups containing a basic nitrogen atom include, but are not limited to, amines (which can be primary, secondary or tertiary) and amides. Preferred are primary alkyl amine groups such as aminoethyl, aminopropyl and the like.
Examples of additives that give enhanced physical properties to mixtures of halobutyl elastomers and filler include proteins, aspartic acid, 6-aminocaproic acid, diethanolamine and triethanolamine. Preferably, the additive should contain a primary alcohol group and a primary amino group separated by methylene bridges, which may be branched. Such compounds have the general formula HO—A—NH 2 ; wherein A represents a C 1 to C 20 alkylene group, which may be linear or branched.
More preferably, the number of methylene groups between the two functional groups should be in the range of from 1 and 4. Examples of preferred additives include mono-ethanolamine and 3-amino-1-propanol.
The amount of filler to be incorporated into the halobutyl elastomer can vary between wide limits. Typical amounts of filler are in the range of from 20 parts to 120 parts by weight, preferably in the range of from 30 parts to 100 parts, more preferably from 40 to 80 parts per hundred parts of elastomer. The amount of the additive used is dependent upon the molecular/equivalent weight of each specific compound. One important factor is the number/weight of nitrogen per unit weight of the compound. The level of nitrogen may range from 0.1 to 5 parts per hundred (phr) of halobutyl rubber, preferably from 0.125 to 1 phr and, more preferably, from 0.3 to 0.7 phr. Up to 40 parts of processing oil, preferably in the range of from 5 to 20 parts, per hundred parts of elastomer, may be present. Further, a lubricant, for example a fatty acid such as stearic acid, may be present in an amount up to 3 parts by weight, more preferably in an amount up to 2 parts by weight.
Carbon black may be present in an amount up to 40 phr. If the mineral filler is silica and it is used as a mixture with carbon black, the silica should constitute at least 55% by weight of the total of silica and carbon black. If the halobutyl elastomer composition of the invention is blended with another elastomeric composition, that other composition may contain more carbon black as a filler.
The halobutyl elastomer, filler and additive are mixed together, suitably at a temperature in the range of from 25 to 200° C. It is preferred that the temperature in one of the mixing stages be greater than 60° C., and a temperature in the range of from 90 to 150° C. is particularly preferred. Normally the mixing time does not exceed one hour; a time in the range from 2 to 30 minutes is usually adequate. The mixing is suitably carried out on a two-roll mill mixer, which provides good dispersion of the filler within the elastomer. Mixing may also be carried out in a Banbury mixer, or in a Haake or Brabender miniature internal mixer. An extruder also provides good mixing, and has the further advantage that it permits shorter mixing times. It is also possible to carry out the mixing in two or more stages. Further, the mixing can be carried out in different apparatuses, for example one stage may be carried out in an internal mixer and another in an extruder.
The enhanced interaction between the filler and the halobutyl elastomer results in improved properties for the filled elastomer. These improved properties include higher tensile strength, higher abrasion resistance, lower permeability and better dynamic properties. These render the filled elastomers particularly suitable for a number of applications, including, but not limited to, use in tire treads and tire sidewalls, tire innerliners, tank linings, hoses, rollers, conveyor belts, curing bladders, gas masks, pharmaceutical enclosures and gaskets.
In a preferred embodiment of the invention, bromobutyl elastomer, silica particles, additive and, optionally, processing oil extender are mixed on a two-roll mill at a nominal mill temperature of 25° C. The mixed compound is then placed on a two-roll mill and mixed at a temperature 60° C. It is preferred that the temperature of the mixing is not too high, and more preferably does not exceed 150° C., since higher temperatures may cause curing to proceed undesirably far and thus impede subsequent processing. The product of mixing these four ingredients at a temperature not exceeding 150° C. is a compound which has good stress/strain properties and which can be readily processed further on a warm mill with the addition of curatives.
The filled halobutyl rubber compositions of the invention, and in particular filled bromobutyl rubber compositions, find many uses, but mention is made particularly of use in tire tread compositions. Important features of a tire tread composition are that it shall have low rolling resistance, good traction, particularly in the wet, and good abrasion resistance so that it is resistant to wear. Compositions of the invention display these desirable properties. Thus, an indicator of traction is tan δ at 0° C., with a high tan δ at 0° C. correlating with good traction. An indicator of rolling resistance is tan δ at 60° C., with a low tan δ at 60° C. correlating with low rolling resistance. Rolling resistance is a measure of the resistance to forward movement of the tire, and low rolling resistance is desired to reduce fuel consumption. Low values of loss modulus at 60° C. are also indicators of low rolling resistance. As is demonstrated in the examples below, compositions of the invention display high tan δ at 0° C., low tan δ at 60° C. and low loss modulus at 60° C.
The filled halobutyl elastomers of this invention can be further mixed with other rubbers, for example natural rubber, butadiene rubber, styrene-butadiene rubber and isoprene rubbers, and compounds contain these elastomers.
The invention is further illustrated in the following examples and the accompanying Figures.
EXAMPLES
Description of Tests:
Abrasion resistance: DIN 53-516 (60 grit Emery paper)
Dynamic Property Testing
Dynamic testing (Tan δ at 0° C. and 60° C., Loss modulus at 60° C.) were carried out using the Rheometrics RSA II. The RSA II is a dynamic mechanical analyzer for characterizing the properties of vulcanized elastomeric materials. The dynamic mechanical properties give a measure of traction with the best traction usually obtained with high values of Tan δ at 0° C. Low values of Tan δ at 60° C., and in particular, low loss modulus at 60° C. are indicators of low rolling resistance.
Cure rheometry: ASTM D 52-89 MDR2000E Rheometer at 3° arc and 1.7 Hz
Permeability: ASTM D 14-34
The invention is further illustrated in the following examples.
Description of Ingredients and General Mixing Procedure:
Hi-Sil 233—silica—a product of PPG
Sunpar 2280—paraffinic oil produced by Sun Oil.
Pro-Cote® 5000 is a low molecular weight, chemically modified soy polymer designed as a multi-functional coating additive and binderproduced by Protein Technologies International, located in St Louis, Mo., USA.
The brominated butyl elastomer (Bayer Bromobutyl® 2030), silica, oil and a bonding compound were mixed on a 6″×12″ two-roll mill with the rolls running at 24 and 32 rpm. The mill roll was set at 25° C., with a total incorporation time of 10 minutes. The mixed compounds were then “heat treated” for a further 10 minutes with the roll temperature at 110° C. The final rubber temperature was 125° C. Curatives were then added to the cooled sample with the mill at 25° C.
Example 1
A number of different additives containing hydroxyl and nitrogen atoms were compared with 3 different silane additives commonly used in elastomer silica compounds. A compound containing no bonding agent was also prepared, as a control sample.
The bonding agents used were:
(i) 6-Amino caproic acid; (ii) Aspartic acid; (iii) Pro-Cote® 5000 (soy protein); (iv) Triethanolamine; (v) 2-Amino-2-methyl-1-propanol; (vi) 3-Amino-1-propanol; and (vii) Monoethanolamine.
The three commonly used silanes used for comparison purposes were:
(a) Amino propyl triethoxy silane; (b) Si69, bis[3-(triethoxysilyl)propyl]- tetrasulfane [(C 2 H 5 O) 3 Si—(CH 2 ) 3 —S 4 —(CH 2 ) 3 —Si(OC 2 H 5 ) 3 ]; and (c) Silquest 1589, bis[3-(triethoxysilyl)propyl]- disulfane (C 2 H 5 O) 3 Si—(CH 2 ) 3 —S 2 —(CH 2 ) 3 —Si(OC 2 H 5 ) 3 ].
Brominated isoprene isobutylene rubber (BIIR) was mixed with the additive, 60 parts per hundred rubber (phr) of silica filler (Hisil 233) and 10 phr of oil extender (Sunpar 2280) on a 6″×12″ mill under the mixing conditions described above. Identical curative ingredients (1 phr of stearic acid and sulfur, and 1.5 phr. of ZnO) were then added on a cool mill to each of the compounds. The compounds were then cured for either t c(90) +10 minutes at 170° C. (for DIN Abrasion testing) or t c(90) +5 minutes at 170° C. and tested. Table 1 shows the product compositions, and physical property data for three commonly used silanes and for a compound containing no filler bonding agent.
The data in Table 1 shows the effect of adding silanes to assist in the dispersion and bonding of the filler in the brominated butyl elastomer. The ratio M300/M100 is commonly used as a relative measure of the degree of filler reinforcement in an elastomer compound (the higher the ratio the higher the reinforcement). M300/M100 for the control (no silane) is 1.6 and for silanes ranges from 5.4 to 7.3.
Table 2 shows the product compositions and physical property data for representative additives used in the present invention.
The data in Table 2 shows that the products of the present invention have M300/M100 values of between 2.4 and 7.0. In comparison with the data in Table 1, this shows that all the additives in Table 2 provide some degree of reinforcement. FIG. 1 , a plot of the stress strain data, also shows this reinforcement.
Examination of the DIN Abrasion test data shows that the additives improve wear, although the sample containing no bonding agent was too soft too test. Preferred additives, exemplified by 3-amino-1-propanol and mono-ethanolamine, show much higher values for Tan δ at 60° C. and much lower values for the loss modulus at 60° C. than the other additives.
Example 2
Comparisons were made for mono-, di-, and tri- ethanolamine in a compound containing BIIR +Hi-Sil 233.
Brominated isoprene isobutylene rubber (BIIR) was mixed with the various additives and 60 phr of silica filler (Hisil 233) on a 6″×12″ mill under the mixing conditions described above. Identical curative ingredients, 1 phr of stearic acid and sulfur, and 1.5 phr. of ZnO, were then added on a cool mill to each of the compounds. The compounds were then cured for either t c(90) +10 minutes at 170° C. (for DIN Abrasion testing) or t c(90) +5 minutes at 170° C. and tested. Table 3 shows the product compositions, and physical property data in comparison with amino-propyl triethoxy silane.
The M300/M100 data in Table 3 shows that the primary amine is better than the secondary amine which is better than the tertiary amine in dispersing and bonding the filler to the BIIR. The mono-ethanolamine also has the highest Tan δ at 60° C. and the lowest values for the loss modulus at 60° C.
Example 3
To investigate the effect of the concentration of the dispersing and bonding agent, the concentration of 3-amino-1-propanol was varied from 1.4 to 2.8 to 5.4 phr.
Brominated isoprene isobutylene rubber (BIIR) was mixed with 3-amino-1-propanol and 60 phr of silica filler (Hisil 233) on a 6″×12″ mill under the mixing conditions described above. Identical curative ingredients, 1 phr. of stearic acid and sulfur, and 1.5 phr. of ZnO, were then added on a cool mill to each of the compounds. The compounds were then cured for either t c(90) +10 minutes at 170° C. (for DIN Abrasion testing) or t c(90) +5 minutes at 170° C. and tested. Table 4 shows the product compositions, and physical property data in comparison with amino-propyl triethoxy silane. The data in Table 4 shows that a level of 2.8 phr. is preferred to that of either 1.4 or 5.4 phr. of 3-amino-1-propanol.
Example 4
To investigate the effect of the number of methylene (—CH 2 —) groups between the amine and the alcohol functional groups, monoethanolamine, 3-amino-1-propanol, and 5-amino-1-pentanol were compared with the same equivalent number of amino groups. The data is shown in Table 5.
The data in Table 5 shows poorer properties for 5- amino-1-pentanol compared to monoethanolamine and 3-amino-1-propanol.
Example 5
To show the effect on compounds with carbon-black as a filler brominated isoprene isobutylene rubber (BIIR) was mixed with 8 phr of various amino-alcohols and amino-acids and 50 phr carbon-black (N234 from Degussa) on a 6″×12″ mill under the mixing conditions described above. As curative ingredients 1 phr. of stearic acid, 0.5 phr of sulfur, 1.3 phr of dibenzothiazyl disulphide (Vulkacit® DM) and 1.5 phr of ZnO were then added on a cool mill to each of the compounds. The compounds were then cured for t c(90) +5 minutes at 170° C. and tested to ascertain the effect of the amino-alcohols/amino acids on the stress at a given strain level (see FIG. 2 : DIN 275=control, DIN 281=6-Amino-caproic acid, DIN 191=2-Amino-1-propanol, DIN 207=3-Amino-1-propanol).
Example 6
To show the effect of substituents on the amino-alcohols in compounds with silica as a filler brominated isoprene isobutylene rubber (BIIR) was mixed with 8 phr of various amino-alcohols and 60 phr of silica filler (Hisil 233) on a 6″×12″ mill under the mixing conditions described above. Identical curative ingredients, 1 phr. of stearic acid and sulfur, and 1.5 phr. of ZnO, were then added on a cool mill to each of the compounds. The compounds were then cured for t c(90) +5 minutes at 170° C. and tested to ascertain the effect of the amino-alcohols on the stress at a given strain level (see FIG. 3 : DMAE=N,N-dimethylethanolamine, MEA=ethanolamine, MEA(HCl)=ethanolamine-HCl adduct, EAE=ethylaminoethanol, MAE=methylaminoethanol.). Furthermore, it was found that DMAE has significant advantages in scorch safety over MEA (see FIG. 4 )
TABLE 1
Additive
(control)
(C)
(b)
(a)
Additive amount (phr.).
0
8.6
9.8
8
STRESS STRAIN (Die C DUMBELLS, cure tc90 + 5 @ 170° C.,
tested @ 23° C.)
Hard. Shore A2 Inst. (pts.)
61
62
59
51
Ultimate Tensile (MPa)
6.6
16.2
16.9
15.2
Ultimate Elongation (%)
890
431
494
309
Stress @ 50 (MPa)
0.89
1.13
1.03
0.95
Stress @ 100 (MPa)
0.87
1.83
1.59
2
Stress @ 200 (MPa)
1.01
4.8
4.23
6.89
Stress @ 300 (MPa)
1.39
9.94
8.88
14.5
M300/M100
1.6
5.43
5.58
7.3
DIE C TEAR (cured tc90 + 5 @ 170° C., tested @ R.T.)
Tear Strength (kN/m)
18.7
25.8
30.3
18.8
DIN ABRASION (cure tc90 + 5 @ 170° C.,)
Abrasion Volume Loss (mm 3 )
NR
235
198
230
sample
deformed
RSA II, TEMPERATURE SWEEP (2° C./min, 60 sec soak, 70 rad/s,
cured tc90 + 5 @ 170° C.)
Tan delta @ 0° C.
0.32
0.65
0.66
0.77
Tan delta @ +60° C.
0.10
0.16
0.16
0.11
Loss modulus @ +60° C.
1.90
0.79
0.63
0.45
MDR CURE CHARACTERISTICS (1.7 Hz, 170 deg. C., 3 arc, 60 mins.)
MH (dN.m)
22.8
34.5
32.8
38.4
ML (dN.m)
14.7
6.7
7.3
11.8
ts 1 (min)
1.02
0.72
0.54
0.66
ts 2 (min)
1.98
0.9
0.66
0.84
t′ 10 (min)
0.86
1.11
0.74
0.94
t′ 50 (min)
5.61
5.84
2.34
3.36
t′ 90 (min)
23.9
22.3
10.8
9.1
t′ 95 (min)
28.6
26.2
13.1
11.0
TABLE 2
Additive
(i)
(ii)
(iii)
(iv)
(v)
(vi)
(vii)
Additive amount (phr.).
4.8
4.8
8
5.4
3.25
2.7
2.2
STRESS STRAIN (Die C DUMBELLS, cure tc90 + 5 @ 170° C., tested @ 23° C.,)
Hard. Shore A2 Inst.
61
60
58
62
64
54
50
(pts.)
Ultimate Tensile (MPa)
13.1
12.9
9.5
16.3
15.8
19.0
17.8
Ultimate Elongation (%)
853
856
702
768
807
453
395
Stress @ 50 (MPa)
0.82
0.82
0.88
0.86
1.02
1.03
0.91
Stress @ 100 (MPa)
0.94
0.94
1.04
1.09
1.27
1.9
1.76
Stress @ 200 (MPa)
1.4
1.39
1.75
1.95
2.23
5.74
5.77
Stress @ 300 (MPa)
2.28
2.32
2.99
3.27
3.96
11.48
12.27
M300/M100
2.4
2.47
2.9
3.00
3.1
6.0
6.97
DIE C TEAR (cured tc90 + 5 @ 170° C., tested @ R.T.)
Tear Strength (kN/m)
48.3
56.0
27.0
51.9
55.2
29.5
25.0
DIN ABRASION (cure tc90 + 5 @ 170° C.,)
Abrasion Volume Loss
615
210
651
543
422
262
423
(mm 3 )
RSA II, TEMPERATURE SWEEP (2° C./min, 60 sec soak, 70 rad/s, cured tc90 + 5 @ 170° C.)
Tan delta @ 0° C.
0.33
0.31
0.45
0.36
0.33
0.55
0.59
Tan delta @ +60° C.
0.13
0.13
0.14
0.11
0.11
0.10
0.11
Loss modulus @ +60° C.
2.23
2.36
1.42
2.27
1.60
0.86
0.77
MDR CURE CHARACTERISTICS (1.7 Hz, 170 deg. C., 3 arc, 60 mins.)
MH (dN.m)
29.6
30.3
25.2
38.5
34.9
42.6
37.2
ML (dN.m)
12.1
11.8
12.4
9.3
9.0
10.4
9.0
ts1 (min)
0.72
0.66
0.96
0.6
0.9
0.48
0.66
ts 2 (min)
0.96
0.9
1.38
0.72
1.2
0.6
0.84
t′ 10 (min)
0.85
0.84
1.05
0.82
1.37
0.71
0.95
t′ 50 (min)
3.08
3.13
5.47
2.55
5.38
3.08
4.26
t′ 90 (min)
9.6
9.6
26.4
8.5
14.6
9.5
12.3
t′ 95 (min)
12.0
12.3
32.8
11.3
17.5
12.0
14.9
TABLE 3
Additive
(a)
(vii)
diethanolamine
(iv)
Additive amount (phr.)
8
2.2
3.9
5.4
STRESS STRAIN (Die C DUMBELLS, t90 + 5 @ 170° C.,
tested @ 23° C.)
Hard. Shore A2 Inst. (pts.)
57
58
67
70
Ultimate Tensile (MPa)
16.5
18.5
20.1
17.6
Ultimate Elongation (%)
278
329
545
658
Stress @ 50 (MPa)
1.17
1.3
1.37
1.17
Stress @ 100 (MPa)
2.43
2.69
2.08
1.46
Stress @ 200 (MPa)
8.75
8.5
5.21
2.94
Stress @ 300 (MPa)
17.92
16.81
10.1
6
300M/100M
7.4
6.2
4.9
4.1
DIE C TEAR (cured tc90 + 5 @ 170° C., tested @ R.T.)
Tear Strength (kN/m)
19.0
27.8
42.1
47.3
DIN ABRASION (cure tc90 + 10 @ 170° C.,)
Abrasion Volume Loss
113
90
138
145
(mm 3 )
RSA II, TEMPERATURE SWEEP (2° C./min, 60 sec soak, 70 rad/s,
cured tc90 + 5 @ 170° C.)
Tan delta @ 0° C.
0.806
0.639
0.436
0.374
Tan delta @ +60° C.
0.109
0.105
0.096
0.085
Loss modulus @ +60° C.
0.397
1.040
1.928
2.309
MDR CURE CHARACTERISTICS (1.7 Hz., 3° arc, 60′ @ 170° C.).
MH (dN.m)
46.9
45.3
46.6
48.0
ML (dN.m)
16.3
12.3
10.8
12.8
ts 1 (min)
0.6
0.48
0.66
0.96
ts 2 (min)
0.78
0.54
0.9
1.26
t′ 10 (min)
0.88
0.65
1.16
1.64
t′ 50 (min)
2.81
2.59
4.8
5.44
t′ 90 (min)
7.5
7.63
13.09
12.63
t′ 95 (min)
9.16
9.48
15.94
14.9
TABLE 4
3-amino-1-propanol (phr.).
1.4
2.8
5.4
STRESS STRAIN (Die C DUMBELLS, t90 + 5 @ 170° C.,
tested @ 23° C.)
Hard. Shore A2 Inst. (pts.)
60
58
79
Ultimate Tensile (MPa)
18.1
18.0
10.0
Ultimate Elongation (%)
402
319
202
Stress @ 50 (MPa)
1.37
1.24
2.42
Stress @ 100 (MPa)
2.3
2.49
4.31
Stress @ 200 (MPa)
6.2
8.14
9.83
Stress @ 300 (MPa)
12.61
16.5
300M/100M
5.5
6.6
DIE C TEAR (cured tc90 + 5 @ 170° C., tested @ R.T.)
Tear Strength (kN/m)
32.6
25.6
30.2
200M/50M
4.5
6.6
4.1
DIN ABRASION (cure tc90 + 10 @ 170° C.,)
Abrasion Volume Loss (mm 3 )
135
109
298
RSA II, TEMPERATURE SWEEP (2° C./min, 60 sec soak, 70 rad/s,
cured tc90 + 5 @ 170° C.)
Tan delta @ 0° C.
0.591
0.644
0.407
Tan delta @ +60° C.
0.106
0.108
0.080
Loss modulus @ +60° C.
1.176
0.888
1.303
MDR CURE CHARACTERISTICS (1.7Hz., 3° arc, 60′ @ 170° C.).
MH (dN.m)
41.0
45.6
61.5
ML (dN.m)
10.1
13.3
26.2
ts 1 (min)
0.72
0.48
0.42
ts 2 (min)
0.84
0.6
0.48
t′ 10 (min)
1.01
0.69
0.58
t′ 50 (min)
4.12
2.4
1.8
t′ 90 (min)
11.4
6.66
5.44
t′ 95 (min)
13.91
8.28
6.7
TABLE 5
Additive
(vii)
(vi)
5-amino-1-pentanol
Additive amount (phr.).
2.2
2.8
3.8
STRESS STRAIN (Die C DUMBELLS, t90 + 5 @ 170° C.,
tested @ 23° C.)
Hard. Shore A2 Inst. (pts.)
58
58
75
Ultimate Tensile (MPa)
18.5
18.0
14.6
Ultimate Elongation (%)
329
319
227
Stress @ 50 (MPa)
1.3
1.24
2.03
Stress @ 100 (MPa)
2.69
2.49
4.16
Stress @ 200 (MPa)
8.5
8.14
12.05
3tress @ 300 (MPa)
16.81
16.5
300M/100M
6.2
6.6
200M/50M
6.5
6.6
5.9
DIE C TEAR (cured tc90 + 5 @ 170° C., tested @ R.T.)
Tear Strength (kN/m)
27.8
25.6
24.9
DIN ABRASION (cure tc90 + 10 @ 170° C.,)
Abrasion Volume Loss (mm 3 )
90
109
173
RSA II, TEMPERATURE SWEEP (2° C./min, 60 sec soak, 70 rad/s,
cured tc90 + 5 @ 170° C.)
Tan delta @ 0° C.
0.64
0.64
0.49
Tan delta @ +60° C.
0.10
0.11
0.09
Loss modulus @ +60° C.
1.04
0.89
0.99
MDR CURE CHARACTERISTICS (1.7 Hz., 3° arc, 60′ @ 70° C.).
MH (dN.m)
45.3
45.6
56.7
ML (dN.m)
12.3
13.3
21.4
ts 1 (min)
0.48
0.48
0.42
ts 2 (min)
0.54
0.6
0.54
t′ 10 (min)
0.65
0.69
0.59
t′ 50 (min)
2.59
2.4
1.78
t′ 90 (min)
7.63
6.66
5.72
t′ 95 (min)
9.48
8.28
7.42 | The invention provides a process for preparing a filled halobutyl elastomer, which comprises mixing a halobutyl elastomer, particles of filler and an additive containing both amino and alcohol functional groups, and curing the filled elastomer with sulfur or other curative systems. This invention has the advantages of (a) not evolving alcohol either during the manufacture or subsequent use of the article manufactured from the compound, and (b) significantly reducing the cost of the compound. | 2 |
CROSS REFERENCE TO RELATED APPLICATION
This application claims priority from Provisional Application No. 60/207,254, filed May 26, 2000.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the preparation of a surface treated carbon black and the compounds derived therefrom. The invention relates to the preparation of a surface treated carbon black which has inherently improved dispersability characteristics and provides rubber compounds with improved dynamic mechanical properties.
2. Discussion of the Prior Art
Improvements in manufacturing of carbon black have allowed for the production of very high surface area carbon black suitable to provide high reinforcement and high levels of wear resistance. With the reduction in the particle size and carbon black structure (the degree of branched connectivity of the carbon black), carbon black becomes increasingly difficult to disperse.
Another phenomenon, carbon black networking, also known as the Payne effect, becomes increasingly prevalent as carbon black content in a rubber compound increases, especially as the particle size decreases and structure increases. This carbon black networking effect is manifested by a dramatic drop in modulus as a function of strain in the rubber compound. This drop in modulus is attributed to a disruption in the carbon black network and is a non-elastic phenomenon. That is to say that the energy required to disrupt this carbon black network is consumed in the disruption of the carbon black aggregate-aggregate interaction and is not recoverable as elastic energy.
The loss in energy due to the Payne effect results in compounds with inherently high loss moduli and, consequently, quite hysteretic. This hysteresis contributes to rolling resistance in pneumatic tire tread compounds increasing fuel consumption.
Previous inventions (Japanese Patent No. 5643/1970, No. 24462/1983, and No. 30417/1968) disclose surface treated carbon black which provide lower cohesive energy density between the particles. However, these materials are not effective in high surface area carbon black. Other patents (U.S. Pat. No. 4,557,306) teach that carbon black modified with Furazan oxides and furazan ring containing compounds provide for improvements in rubber to filler interaction but do not contribute to improvements in the dispersability of the carbon black. And finally, U.S. Pat. No. 4,764,547, teaches that compounds with lower viscosity (thus improved processability) and improved reinforcement properties can be achieved through the use of high surface area carbon black treated with certain amine compounds or quinoline compounds.
Other carbon black coupling agents are known in the art. See, for example T. Yamaguchi et al. in Kautschuk Gummi Kunststoffe , Vol. 42, No. 5, 1989, pages 403-409, which describes a coagent called Sumifine® (i.e. N,N′-bis(2-methyl-2-nitropropyl)-1,6-diaminohexane), and L. Gonz{acute over (a )}lez et al. in Rubber Chemistry and Technology , Vol. 69, 1996, pages 266-272. These agents are not used in common practice.
U.S. Pat. No. 4,764,547 teaches that carbon black treated with conventional antidegradants used in the tire industry can afford an improvement in mixing efficiency. These antidegradants are divided into substituted amines such as paraphenylene diamine and quinoline. Both classes of antidegradants are known as primary antidegradants and function by donating a hydrogen atom to a radical.
The use of an amine compound for carbon surface modification is also disclosed in Japanese abstract J6 2250-073-A.
Carbon black can be difficult to disperse in polymers when the surface area is high. The rate of dispersion of carbon black in polymers is proportional to the viscosity of the polymer, that is, a high viscosity polymer provides faster rates of carbon black dispersion. In the cases of isoprene based rubbers and natural rubber, long mixing time increases the amount of heat generated in the compound and thus reduces viscosity and thus the rate and extent of carbon black dispersion. One technique to overcome this difficulty is to mix carbon black into the polymer several times in internal mixers for short intervals each time. This provides for less time for heat to be generated in the mixer and thus the amount of viscosity reduction is minimized and dispersion is improved, but increasing the number of mixing steps also increases the complexity, time required and expense of the process.
SUMMARY OF THE INVENTION
In its primary embodiments, the present invention provides compositions comprising a combination of carbon black and at least one surface treating agent selected from the group consisting of quinone compounds, quinoneimine compounds and quinonediimine compounds.
In its second embodiments, the present invention comprises the methods of combining the surface treating agent with the carbon black.
Third embodiments of the present invention relate to compositions resulting from the addition of the above combination of carbon black and one or more surface treating agents to natural or synthetic polymers.
In its fourth embodiments, the present invention relates to methods of dispersing carbon black in a natural or synthetic polymer composition, to achieve increased dispersibility, improved mixing efficiency and improved processability of the composition, comprising treating the surface of carbon black with at least one surface treating agent selected from the group consisting of quinone compounds, quinoneimine compounds and quinonediimine compounds, or mixtures thereof, and mixing the treated carbon black with the polymer composition.
Other embodiments of the invention encompass details about relative amounts of reactants, surface treating agents, carbon black, rubber compositions and methods of combining carbon black and surface treating agents and dispersing the carbon black into the polymer composition all of which are hereinafter disclosed in the following discussion of each of the facets of the invention.
DETAILED DESCRIPTION OF THE INVENTION
The invention provides for the preparation of carbon blacks treated with at least one surface treating agent selected from a class of quinone, quinonediimine or quinoneimine compounds. This treated carbon black shows dramatic improvements in dispersability (as measured by both rate of dispersion and extent of dispersion), improved mixing efficiency and improved processability over carbon black not treated with the surface treating agent. The treated carbon black: enhances the formation of bound rubber in compositions such as natural or synthetic elastomers, plastics or blends thereof and, in particular, butadiene-based rubber, providing improved reinforcement characteristics. The vulcanizates prepared therefrom exhibit improved dynamic mechanical properties as compared to vulcanizates prepared with carbon black not treated with the surface treating agent.
Increasing the surface area of carbon blacks leads to improved treadwear, while decreasing the structure improves tear resistance and fatigue crack growth resistance. However, increasing surface area and/or decreasing structure in carbon blacks makes mixing to adequate levels of dispersion even more difficult. A number of additives such as processing oils, amine antidegradants and furazans can increase the rate of filler incorporation, enhance processability or improve polymer to filler interactions, but do not provide all three of those desireable properties.
High shear and/or long mixing cycles are required to obtain optimum dispersion of fillers such as carbon blacks in rubber compounds. For example, adequate dispersion of N121 carbon black in natural rubber (NR) typically cannot be achieved in a single pass. Therefore, to obtain acceptable carbon black dispersion, most rubber compounds are mixed using two or more mixing passes. This increases the cost of the compound as well as limiting mixing capacity.
This invention focuses on the use of a quinone, quinonediimine or quinoneimine antidegradant as a surface treatment for carbon black. These surface treated carbon blacks exhibit improved mixing characteristics and improved processability, including substantial improvements in dispersability. Improved processability results from the viscosity reduction in natural rubber resulting from use of the treated carbon black. Viscosity reduction is due to peptization, i.e., chain-scission, which results in a decrease in molecular weight. In addition to improved dispersion, this class of chemicals also imparts improvements in bound rubber in natural and synthetic elastomers.
We have found that surface treating carbon black with quinone, quinoneimine, or quinonediimine results in a product that disperses faster in a synthetic and natural rubber tread compound. It is intended that a very broad class of quinones, quinoneimines, or quinonediimines as dispersion agents are suitable for use in the invention, limited primarily by considerations of practicality of physical properties of the agents or the chemical activity of or stearic hindrance caused by various substituted groups on the molecules of the dispersion agents. Preferably, the surface treating agent is a quinoneimine or quinonediimine, more preferably a quinonediimine. With regard to all of the above surface treating agents, the para isomer is preferred.
Effective quinones for use in the invention include those represented by the following formulas Ia and Ib:
wherein R 1 , R 2 , R 3 , and R 4 are the same or different and are selected from hydrogen, hydroxyl, alkyl, alkoxy, aryloxy, alkenyl, cycloalkyl, aryl, aralkyl, alkaryl, alkylamino, arylamino, heterocycle, acyl, aroyl, cyano, halogen, thiol, thioalkyl, thioaryl, amino, nitro, sulfonate, sulfone, sulfonamide, carboxylic acid, alkyl ester and, aryl ester, and the alkyl moieties in the R 1 , R 2 , R 3 , and R 4 groups may be linear or branched and each of the R 1 , R 2 , R 3 , and R 4 groups may be further substituted where appropriate.
Effective quinoneimines for use in the invention include those represented by the following formulas II a and II b :
wherein R 1 is selected from hydrogen, hydroxyl, alkyl, alkoxy, aryloxy, alkenyl, cycloalkyl, aryl, aralkyl, alkaryl, alkylamino, arylamino, heterocycle, acyl, aroyl, cyano, halogen, thiol, thioalkyl, thioaryl, amino, nitro, sulfonate, sulfone, sulfonamide, carboxylic acid, alkyl ester and, aryl ester, wherein the alkyl moieties in the R 1 groups may be linear or branched and each of the R 1 groups may be further substituted where appropriate; further wherein R 2 , R 3 , R 4 , and R 5 are the same or different and are selected from hydrogen, hydroxyl, alkyl, alkoxy, aryloxy, alkenyl, cycloalkyl, aryl, aralkyl, alkaryl, alkylamino, arylamino, heterocycle, acyl, aroyl, cyano, halogen, thiol, thioalkyl, thioaryl, amino, nitro, sulfonate, sulfone, sulfonamide, carboxylic acid, alkyl ester and, aryl ester, wherein the alkyl moieties in the R 2 , R 3 , R 4 , and R 5 groups may be linear or branched and each of the R 2 , R 3 , R 4 , and R 5 groups may be further substituted where appropriate.
Effective quinonediimines for use in the invention include those represented by the following formulas III a and III b :
wherein R 1 and R 2 are independently selected from hydrogen, hydroxyl, alkyl, alkoxy, aryloxy, alkenyl, cycloalkyl, aryl, aralkyl, alkaryl, alkylamino, arylamino, heterocycle, acyl, formyl, aroyl, cyano, halogen, thiol, alkylthio, arylthio, amino, nitro, sulfonate, alkyl sulfonyl, aryl sulfonyl, amino sulfonyl, hydroxy carbonyl, alkyloxycarbonyl and aryloxycarbonyl, wherein the alkyl moieties in the R 1 and R 2 groups may be linear or branched and each of the R 1 and R 2 groups may be further substituted; further wherein R 3 , R 4 , R 5 , and R 6 are the same or different and are selected from hydrogen, hydroxyl, alkyl, alkoxy, aryloxy, alkenyl, cycloalkyl, aryl, aralkyl, alkaryl, alkylamino, arylamino, heterocycle, acyl, aroyl, cyano, halogen, thiol, alkylthio, arylthio, amino, nitro, sulfonate, alkyl sulfonyl, aryl sulfonyl, aminosulfonyl, hydroxycarbonyl, alkyloxycarbonyl and aryloxycarbonyl, wherein the alkyl moieties in the R 3 , R 4 , R 5 , and R 6 groups may be linear or branched and each of the R 3 , R 4 , R 5 , and R 6 groups may be further substituted where appropriate.
It is preferred that R 1 and R 2 are independently selected from alkyl, alkenyl, cycloalkyl, aryl, aralkyl and alkaryl for quinonediimines.
It is preferred that the number of carbon atoms in any and all of the above R groups be from 0 to about 25.
The most preferred surface treating agent is N-phenyl-N′-1, 3 dimethylbutyl-p-quinonediimine.
Carbon black suitable for use in the invention has a preferred surface area of from about 9 to about 420 m 2 /g, and most preferred from about 40 to about 140 m 2 /g, as measured by the nitrogen adsorption method (ASTM D 4820). The carbon black may be agglomerated in the form of beads or powder. The carbon black types have a preferred particle size of from about 8 to about 300 nm average particle size and most preferably from about 12 to about 100 nm.
The surface of the carbon black is preferably treated with from about 0.01 to about 150.0 parts by weight, most preferably from about 0.5 to about 8.0 parts by weight, of the surface treating agent per 100 parts by weight of carbon black.
The surface treating agents may be combined with carbon black beads or powder by spraying the beads or powder with the surface treating agents at a temperature of from above the melting point of the surface treating agent to a temperature below its decomposition temperature. The combination may also be effected by dissolving the surface treating agent in an appropriate solvent and applying the resulting solution to the beads or powder followed by removal of the solvent to produce the surface treated carbon black. Appropriate solvents include but are not limited to a hexane, THF, toluene, benzene and methanol.
For best results, the surface treating agents should be added to the carbon black at any point from the production site of the carbon black to prior to the mixing of the carbon black and surface treating agent combination with the polymeric material. Such treatment may occur at the entrance of the mixing device in which the carbon black and polymeric material are mixed.
Without intending to be limited to any particular theory, we believe that the surface treated carbon black of our invention works in a very special way in polymer compositions that accounts for their superior effectiveness. There is some evidence indicating the surface treating agents are bound into the polymer structure of the rubber rather than just acting as a wetting agent which is the case with the anti-degradents of U.S. Pat. No. 4,764,547.
To explain further, our carbon black surface treating agents contain a non-nucleophilic nitrogen and is an electron acceptor. As mentioned above, this is distinguished from the anti-degradents of U.S. Pat. No. 4,764,547 that contain nucleophilic nitrogen and are electron donors and/or hydrogen atom donors. Our surface treating agents react differently with radicals, i.e. by addition reactions with the radicals, the effect being an active rather than an inert surface treatment. This results not only in dispersion improvement, but also in the modification of the rheological and physical properties of a rubber compound.
The natural or synthetic polymers used in accordance with the invention may be natural rubber (NR), a synthetic rubber such as isoprene rubber (IR) or a mixture thereof. Such polymers may be natural or synthetic elastomers, plastics, or blends thereof. Preferably, the rubber composition comprises NR. Blends of a polyisoprene rubber with one or more other rubbers such as polybutadiene rubber or butadiene rubber (BR), styrene-butadiene rubber (SBR), and a mixture of BR and SBR may also be used.
In this application, the abbreviation “phr” means the number of parts by weight per 100 parts by weight of rubber. For example, in the case of a rubber blend, it would be based on 100 parts by weight of total rubber. “PhCB” means the number of parts by weight per 100 parts by weight of carbon black.
A sulfur-vulcanizable rubber composition typically contains carbon black in an amount from about 10 to about 100, preferably about 20 to about 80, more preferably about 40 to about 80 phr. It may also contain silica in an amount of 0 to about 80, preferably 0 to about 60, more preferably 0 to about 50 phr. It may also contain a silane coupling agent for silica. The typical amount of the silane coupling agent employed is between about 5 to about 20% by weight of the silica loading.
EXAMPLES
The following examples illustrate the practice and benefits of our invention.
Initially the surface treated carbon black product was evaluated using laboratory scale mixing equipment. This was followed by factory scale mixing experiments of NR and SBR tread formulations.
The following surface treated products were prepared by directly spraying quinondiimines (in this case N-phenyl-N′-1,3 dimethylbutyl-p-quinonediimine (Compound A)) onto the surface of carbon black.
For initial laboratory evaluations, a sample consisting of 4.4 PhCB of Compound A was used.
Example 1
Laboratory Evaluation of Surface Treated Carbon Black in NR.
The NR formulations used for initial evaluation are given in Table 1.
TABLE I
NR Tread Formulation for Lab. Evaluation of
Surface Treated N-121 Carbon Black
NR Surface Treated
NR Control
Carbon Black
First Pass Mix
Phr
First Pass Mix
Phr
SMR CV60 1
100
SMR CV 60
100
N-121 2
50
N-121 (4.4 PhCB
52.2
Compound A)
Zinc Oxide
4.0
Zinc Oxide
4.0
Stearic Acid
1.5
Stearic Acid
1.5
Microcrystalline
1.0
Microcrystalline 1.0
wax
wax
6PPD 3
2.2
Total
158.7
Total
158.7
Final Mix
Phr
Final Mix
Phr
First Pass Mix
158.7
First Pass Mix
158.7
TBBS 4
1.6
TBBS
1.6
Sulfur
1.2
Sulfur
1.2
Total
161.5
Total
161.5
1 Standard Malaysian rubber
2 This and all following carbon black designations are in a accordance with the ASTM Classification system
3 N-(1,3-dimethylbutyl)N′-phenyl-p-phenylenedediamine
4 N-tert-butyl-2 benzothiazolesulfenamide
1 Standard Malaysian rubber
2 This and all following carbon black designations are in accordance with the ASTM Classification system
3 N-(1, 3-dimethylbutyl) N′-phenyl-p-phenylenediamine
4 N-tert-butyl-2 benzothiazolesulfenamide
The degree of carbon black dispersion found for the first pass mixes are compared in Table 2 below.
Dispersion analysis is carried out in accordance with ASTM D 2663-93 Test Method C, Annual Book of ASTM Standards, Vol., 09.01, Sect. 9, p. 468,1993, and is reported as dispersion index (DI).
TABLE 2
Dispersion Index and Mooney Viscosity for NR Tread Compound
N-121/
N-121 +
COMPOUND
COMPOUND
N-121 + 6-
A Surface Treated
A Added in-
PPD Added
Product
situ
in-situ
Property
Treated
Control
Control
Master batch
Properties
DI (Master batch)
91
77
77
Frequency (p/cm)
27
51
51
Height (micrometers)
2.4
2.3
2.3
F 2 H
1735
5872
5814
Compound Properties
Mooney Viscosity M L
86
87
92
(1 + 4)
100% Modulus (MPa)
3.3
3.7
3.6
The data in Table 2 shows that Compound A surface treated carbon black yields an improved dispersion index of 91, the control masterbatch that was mixed with 6-PPD (an amine as taught in the prior art) had a dispersion index of 77. The average height (H) of the peaks (undispersed carbon black) for all the samples was similar (about 2.3 micrometers). However, the frequency of peaks/cm (P/cm) was significantly lower for the Compound A surface treated carbon black (27 vs. 51). Hence F 2 H, which is used to calculate the dispersion index was also lower. The additional benefits observed were reductions in viscosity and modulus. A reduction in viscosity would make natural rubber easier to process, while a reduction in modulus would permit higher filler loading and hence potential material cost savings.
With further regard to Table 2, “Added in-situ” means that the surface treating agent was added to the masterbatch rather than used to treat the carbon black.
Example 2
Large Scale Evaluation of Surface Treated Black in NR.
This carbon black treated with Compound A was then mixed in an 80 L internal mixer (Farrell model FT-80C) and compared to a compound prepared with the N-121 not treated with Compound A. The formulations used are given in Table 3 below.
TABLE 3
NR Tread Formulations for Large Scale Evaluation
of Surface Treated N-121 Carbon Black
NR Surface Treated
NR Control
Black
Master Batch
Phr
Masterbatch
Phr
SIR 10 5
100
SIR 10
100
N-121
50
N-121 (4.4
54
PhCB
Compound A)
Zinc Oxide
4
Zinc Oxide
4
Stearic Acid
1.5
Stearic Acid
1.5
Microcrystalline
1
Microcrystalline
1
wax
wax
Total
156.5
Total
160.5
Final Mix
Phr
Final Mix
Phr
Masterbatch
156.5
Masterbatch
160.5
TMQ 6
0.7
TMQ
0.7
TBBS
1
TBBS
1
Sulfur
2
Sulfur
2
6PPD
2
Total
162.2
Total
164.2
5 Standard Indonesian Rubber
6 2,2,4-Trimethyl-1,2-dihydroquinoline, an antioxidant
5 Standard Indonesian Rubber
6 2,2,4-Trimethyl-1,2-dihydroquinoline, an antioxidant
Ingredients for the ‘first mix’ were mixed with the rotor and wall temperature at 120° F., ram pressure at 60 PSI, and fill factor (volume % of the mixer that is filled) of 73%. The batches were mixed to a temperature of 350° F. as measured by a thermocouple located in the mixer. The batches were sheeted on a two-roll mill and allowed to cool. The average of three mixes each are reported below for the control black and the black treated with Compound A.
As seen in Table 4 below, mixing times in the second stage are reduced ˜40-45% when the carbon black is treated with Compound A. Overall, total mixing times are reduced by 18 to 27% (first pass mix time plus second pass mix times).
TABLE 4
Large Scale Mixing Characteristics of Surface Treated Carbon Black Product
(AB)
Master Batch (first mix)
Final Mix (second mix)
Rotor
Dump
Dump
Rotor
Dump
Dump
Speed
Temp
Time
Speed
Temp
Time
Dispersion
Compound
Rpm
° F.
Seconds
Rpm
° F.
Seconds
Index
Control
70
358
127
26
225
187
70
AB
70
360
124
26
226
106
80
AB
52
357
152
26
217
106
83
The ‘first mixes’ were allowed to relax for at least 4 hours but not more than 48 hours then mixed again. The rotor and wall temperatures were set to 120° F., ram pressure @40 PSI, and the fill factor was 69%. The mixes were mixed to a temperature of 210° F. as measured by a thermocouple located in the mixing chamber.
The above batches were cured in a rubber process analyzer (RPA model 2000) at 150° C. for 15 minutes. Dynamic mechanical properties were measured by a strain sweep having a frequency of 100 cycles per second. As expected, slight reductions in G′ (elastic component of shear modulus) occurred while greater reductions in G″ (viscous component of shear modulus) were observed. Averaging two mixes prepared as described above gave the reductions in loss tangent as a function of strain as shown in the following Table 5:
The above batches were cured in a rubber process analyzer (RPA model 2000) at 150° C. for 15 minutes. Dynamic mechanical properties were measured by a strain sweep having a frequency of 100 cycles per second. As expected, slight reductions in G′ (elastic component of shear modulus) occurred while greater reductions in G″ (viscous component of shear modulus) were observed. Averaging two mixes prepared as described above gave the reductions in Loss Tangent (Tan D) as a function of strain as shown in the following Table 5:
TABLE 5
RPA Dynamic Mechanical Properties Measured at 60° C.
Surface
Percent Change in
Control 70 RPM
Treated Carbon Black −70
Properties
Average of two mixes
RPM Average of two mixes
Compared to Control
% Strain
G′ kPa
G″ kPa
Tan D
G′ kPa
G″ kPa
Tan D
G′
G″
Tan D
0.56
3223
244
0.0755
2745
182
0.0660
−14.8
−25.5
−12.6
0.98
2880
240
0.0833
2522
180
0.0715
−12.4
−25.0
−14.2
1.95
2499
266
0.1065
2235
202
0.0903
−10.6
−24.1
−15.2
5.02
2050
260
0.1269
1873
207
0.1105
−8.6
−20.4
−13.0
10.04
1799
252
0.1398
1669
204
0.1220
−7.2
−19.0
−12.7
24.97
1393
349
0.2504
1331
314
0.2362
−4.5
−9.8
−5.7
49.94
1122
337
0.3005
1080
318
0.2940
−3.7
−5.7
−2.2
Loss tangent is proportional to energy loss or hysteresis, is measured as the ratio of G″ (loss modulus, kilo Pascals) to G′ (storage modulus, kilo Pascals) and is termed loss tangent or Tan D. Tan D is proportional to rolling resistance and thus fuel efficiency of a tire compound. Compounds with a lower Tan D measured at 60° C. will have lower rolling resistance and thus be more fuel efficient.
Example 3
Laboratory Scale Evaluation of an NR/BR (BR is butadiene rubber) Sidewall Compound.
A sidewall recipe containing NR/BR in a 55/45 parts ratio and 50 phr of N550 carbon black was mixed on a laboratory scale and evaluated for physical properties and carbon black dispersion. The recipe is shown in table 6 below. The physical properties and dispersion information are shown in table 7. The batch mixed using the Compound A treated N550 exhibited an improvement in carbon black dispersion but not the reduction in viscosity or 100% modulus that was seen with the NR tread recipe.
TABLE 6
NR/BR Sidewall Recipe for Laboratory Evaluation
Compound A Treated N550 Carbon Black
NR/BR Surface Treated
NR/BR Control
Black
Master Batch
Phr
Master Batch
phr
SMR CV-60
55.0
SMR CV-60
55.0
Butadiene Rubber
45.0
Butadiene Rubber
45.0
N-550
50.0
N-550 (4.6 PhCB
52.3
6Compound A)
Zinc oxide
3.0
Zinc oxide
3.0
Stearic acid
1.5
Stearic acid
1.5
6-PPD
2.3
6-PPD
0.0
Napthenic oil
10.0
Napthenic oil
10.0
Microcrystalline
2.0
Microcrystalline
2.0
wax
wax
Total
168.8
Total
168.8
Final Mix
Phr
Final Mix
phr
Master Batch
168.8
Master Batch
168.8
TBBS
1.0
TBBS
1.0
Sulfur
1.6
Sulfur
1.6
Total
171.4
Total
171.4
TABLE 7
Dispersion Index and Mooney Viscosity for NR/BR Sidewall Compound
N550/COMPOUND
A Additive
N550 + 6-PPD
Product
Added in-situ
Property
Treated
Control
Masterbatch Properties
DI (Masterbatch)
98.4
96.5
Frequency (p/cm)
27
47
Height (micrometers)
2.2
1.7
F 2 H
1604
3755
Compound Properties
Mooney Viscosity
45
46
M L (1 + 4)
100% Modulus (MPa)
2.2
1.9
Example 4
Large Scale Evaluation of an SBR (styrene butadiene rubber) Tread Recipe
The SBR recipe mixed and tested is detailed in Table 8 below. The batches were mixed to a first pass drop temperature of 350° F. using a fill factor of 69%. Rotor speeds were adjusted in order to produce a range of mix quality; i.e., to produce under mixed and over-mixed batches for comparison to properly mixed batches. The second pass mixes were dropped at 210° F. Mix cycle time, dispersion index, and Mooney viscosities were compared for each of the second pass mixes shown in Table 9 below. The second pass mix times were found to average ˜40-50% shorter mixing times for the batches containing the Compound A treated carbon black. This leads to approximately a 20% decrease in the overall mix cycle times (first pass plus second pass times). No difference was found in the dispersion index between the control compounds and the compounds containing the treated carbon black. However, very large differences were found for the Mooney viscosities of the compounds containing the treated carbon black and the control compounds. Unlike the case of the NR tread compound, the Mooney viscosities of the SBR compounds containing surface treated carbon black were significantly increased over those of the corresponding control batches. This indicates either that the Compound A treatment has promoted greater interaction between the polymer and the carbon black or that it has prevented significant breakdown of the polymer during the mixing process. In either case treadwear should be improved versus the control compound.
TABLE 8
SBR Tread Compounds for Large Scale Evaluation
of N-121 Surface Treated Carbon Black
SBR Surface Treated
SBR Control
Carbon Black
First Pass Mix
Phr
First Pass Mix
Phr
SBR
100
SBR
100
N-121
50
N-121 (4.4
52.2
Compound A)
Zinc Oxide
3.0
Zinc Oxide
3.0
Stearic Acid
2
Stearic Acid
2
Aromatic oil
10
Aromatic oil
10
Microcrystalline
1.0
Microcrystalline
1.0
wax
wax
166.0
168.2
Final Mix
Phr
Final Mix
Phr
First Pass Mix
166.0
First Pass Mix
168.2
TBSI 7
1.7
TBSI
1.7
TMTD 8
1.42
TMTD
1.42
Sulfur
2.07
Sulfur
2.07
6PPD
2.2
6PPD
0.0
173.39
173.39
7 N-tert-Butyl-di(2-benzothiazolesulfen)imide
8 Tetramethylthiuram disulfide
TABLE 9
Mix Cycle and Dispersion Data for SBR Tread Compound
Second Pass
Master Batch
Bound
Initial
ML
Min. Mooney
Rotor
Dump
Dump
Rotor
Dump
Dump
Rubber
Mooney
1 + 4
@ 121° C.
Speed
Temp
Time
Speed
Temp
Time
Dispersion
Volume
Vis. @
@
(Mooney
Compound
Rpm
° F.
Seconds
Rpm
° F.
Seconds
Index
Fraction
121° C.
121° C.
scorch test)
Control
70
366
118
26
223
79
88.0
0.2480
121
88
88
52
362
170
26
223
89
93.0
0.2541
121
88
88
105
366
79
26
220
80
80.0
0.2540
120
89
88
Surface
70
368
98
26
201
48
85.0
0.4016
156
114
111
Treated
52
366
165
26
205
51
92.0
0.3775
153
106
103
Carbon
105
368
76
26
201
40
80.0
0.4018
170
127
121
Black | The invention comprises a composition comprising a combination of carbon black and at least one surface treating agent selected from the group consisting of quinone compounds, quinoneimine compounds and quinonediimine compounds, as well as methods of obtaining the composition and the use of the composition in dispersing carbon black in a natural or synthetic polymer. The composition achieves increased dispersibility and improved mixing characteristics of the carbon black and improved processability of the carbon black containing polymer. | 2 |
BACK GROUND OF THE INVENTION
The present invention relates to a connector for an inflation device compatible with several types of valve without manual intervention, in particular for a bicycle pump type inflation device.
DESCRIPTION OF THE RELATED ART
Several types of valve are used for inflating bicycle tyres. In particular, two types are commonly used and are known by the name of “Bicycle-type” valves (Presta) and “Car-type” valves (Schrader). Bicycle-type valves are small diameter valves (corresponding to an approximately 6.5 mm rim hole) defined by French standard NF R99-035 of May 1974, used particularly for bicycles known as racing bicycles, with narrow rims. Car-type valves have a larger diameter (corresponding to an approximately 9 mm rim hole), are defined by French standard NF R99-031 of May 1974, and are used particularly for mountain bikes, mopeds and cars. In addition to their form, these valves also function differently.
Several devices exist to inflate tyres fitted with one of these valves. However, these devices have the drawback that the type of valve must be determined in advance and the device must then be adjusted to fit the type of valve used by a deliberate action on the part of the user, for example changing or adjusting a connection means on the valve. Pump users require pumps fitted with “intelligent” connection means, i.e. connectors that allow the user to fit the pump without concerning himself with the type of valve that a tyre is fitted with.
SUMMARY OF THE INVENTION
The purpose of this invention is to propose a connector for an inflation device compatible with several types of valve, for example that adjusts to bicycle-type valves and car-type valves without user intervention.
According to the invention, such a connector for an inflation device to a tyre valve comprises a hollow stopper to operate valve opening means and an elastically deformable seal. The connector is characterised in that the seal has a lip designed to immobilise the stopper during inflation, if the aforementioned valve is of a first type, or to deform and form a seal around the valve on inflation if the aforementioned valve is of a second type. The first type may correspond to a car-type valve and the second to a bicycle-type valve.
If the aforementioned valve is of the first type, the lip may also form a seal between an inner edge of the valve and the stopper, with an air intake from the inflation device to the valve being formed through the hollow stopper.
The connector may advantageously comprise a pipe, for air, in which the stopper is movably mounted. When no valve is connected, the lip surrounds the stopper in an initial position. The connector then also has means for retracting the stopper into the pipe on connection to the second type of valve, so that the aforementioned valve can be surrounded by the lip, and means for returning the stopper to its initial position when the aforementioned valve is withdrawn. The connector will preferably comprise means of deforming the seal.
Thus, the means to deform the seal may comprise a cover and a body between which the seal is arranged, the body being movable in relation to the cover, so that it can move closer to the cover, compressing the seal, or move away from the cover, decompressing the seal. This can be achieved through operating controls to move the body relative to the cover, for example using a cam lever, which can be locked in a first position in which the seal is not deformed or slightly deformed, or in a second position in which the seal is significantly deformed.
The seal may advantageously have a socket between a socket opening and the lip, such opening being designed to introduce the valve into the socket, and the socket being able to contract around the valve when the seal is deformed, in order to hold the aforementioned valve during inflation. Preferably, the seal is a volume of revolution around an axis of revolution and the body is movable in translation along this axis relative to the cover. The seal may also be provided with a convex tapered rear surface, on the opposite side to the seal socket opening, facing a concave tapered front surface on the body, so that when the body compresses the seal, the deformation of the seal is increased so that the lip contracts more tightly around the stopper or the valve, as the case may be.
Instead of being fitted directly to the tyre, the valve can be mounted on an air chamber or any other item capable of being inflated. Thus, whenever the term “tyre” is used below for the sake of simplicity, it should be taken to mean “tyre, air chamber or any other item capable of being inflated”.
BRIEF DESCRIPTION OF THE DRAWINGS
The description below, which relates to non-limitative examples, contains other specific features and advantages of the invention.
In the appended drawings:
FIG. 1 is a perspective cross-section representation of a pump connector according to the invention;
FIG. 2 is an axial cross-section of a seal for the connector in FIG. 1 ;
FIGS. 3 to 5 are cross-section representations of stages of the connection of the device in FIG. 1 to a car-type valve;
FIG. 6 is a detail of FIG. 5 , with the car-type valve being connected to the device;
FIGS. 7 to 9 are cross-section representations of stages of the connection of the device in FIG. 1 to a bicycle-type valve.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a pump connector 100 . It is designed for connecting a pump to a valve 201 , 202 , through which compressed air produced by the pump can be introduced into the tyre. It allows for the pump to be connected either to a car-type valve 201 or a bicycle-type valve 202 (see FIGS. 3–9 ). This pump connector comprises an approximately cylindrical body 1 around an axis X 1 and a housing 2 . The housing 2 has a cylindrical inner surface 21 around an axis X 2 . The body 1 is mounted in the housing 2 , fitted in and sliding on the inner surface 21 and along the axis X 1 merged with the axis X 2 . A mounting area 10 extends transversally from the body 1 to allow for the pump connector 100 to be mounted on a piston/cylinder assembly (not shown), extending transversally along the axis X 1 , to form the bicycle pump.
The body 1 has a cylindrical pipe 13 , with an axis X 1 and a diameter D 1 , opened in a concave tapered front face 11 of the body and closed at the opposite end by a base 131 . A channel 14 , extending transversally to the axis X 1 , connects the pipe 13 and the mounting area 10 . Thus, the pressurised air provided by the piston/cylinder assembly can be carried through the channel 14 , the pipe 13 and then the front face 11 of the body 1 .
The pump connector 100 also comprises a seal 3 mounted along the axis X 1 between an annular cover 4 screwed to the housing 2 and the front face 11 of the body 1 . The seal has a shape of revolution around the axis of the seal X 3 . The seal is mounted so that its axis of revolution X 3 merges with the axis of revolution X 1 of the body 1 . The seal 3 is made from an elastically deformable elastomer type material. The cover has a circular opening 41 to introduce the valve to which the pump is to be connected into the seal.
A hollow stopper 8 is mounted so that it can slide in the pipe 13 . A helical compression spring 9 , fitted compressed between the hollow stopper 8 and the base 131 , tends to push the hollow stopper 8 out of the pipe 13 through the front face 11 . The seal 3 is designed to prevent the hollow stopper 8 from coming out of the pipe 13 through the front face 11 . The pipe 13 has a stub 132 , extending axially from the base 131 inside the pipe 13 , around which the rear end of the spring 9 is wrapped to position it transversally relative to the axis X 1 .
The pump connector 100 also has a lever 6 that comprises a cam 61 and a handle 62 . The lever is mounted so that it can pivot around a pivot 7 with an axis X 7 perpendicular to the axis X 1 and fixed relative to the housing 2 . The cam 61 has a thrust surface 611 , the distance from the axis X 7 of the pivot of which varies progressively from a first distance L 1 to a second distance L 2 , the second distance L 2 being greater than the first distance L 1 . The thrust surface 611 is arranged so that when the handle 62 on the lever is lowered parallel to the piston/cylinder assembly, i.e. perpendicular to the axis of revolution X 1 of the body 1 , the first distance L 1 is measured parallel to the axis X 1 , and when the handle of the lever is raised, parallel to the axis of revolution X 1 of the body 1 , the second distance L 2 is measured parallel to the axis X 1 .
When the handle is moved in rotation R around the pivot 7 from its lowered position to its raised position, the thrust surface 611 presses against a rear face 12 of the body 1 , on the opposite side from its front face 11 along its axis X 1 . Thus, the body 1 moves inside the housing 2 under the progressive thrust of the thrust surface 611 towards the cover 4 so that the seal 3 is compressed between the front face 11 of the body 1 and the cover 4 .
The seal 3 will now be described, with particular reference to FIG. 2 . In FIG. 2 , the seal is shown uncompressed and free of any external stress. The seal 3 has a cylindrical outer surface 32 . This surface 32 is designed so that it can slide on the inner surface 21 of the housing 2 . The seal is axially delimited by a convex rear compression surface 31 , serving as a bearing surface for the front face 11 of the body 1 , and to the front by a bearing surface 34 serving as a bearing for the seal 3 on the cover 4 . The compression surface 31 is tapered, with the same dimensions as the tapered front face 11 of the body 1 . The bearing surface 34 is a flat annular surface, perpendicular to the axis X 3 of the seal, the outer diameter of which is the same as the diameter of the outer surface 32 and the inner diameter D 2 , approximately the same as the diameter of the opening 41 of the cover 4 , is the same as the diameter of a socket opening 39 to introduce the valve into the seal 3 . The diameter D 2 is approximately the same as the diameter of the stem of a car-type valve 201 (approx. 7.7 mm).
The seal 3 has an axial hole between the compression surface 31 and the bearing surface 34 with a complex shape of revolution of axis X 3 , which can be broken down into three successive areas. A first area 33 is an axial extension of the pipe 13 . This first area is made up of a cylindrical extension surface 331 , with the same axis and the same diameter D 1 as the pipe 13 . This extension surface extends between the compression surface 31 , of which it defines an inner diameter D 1 , and an annular stop surface 332 , extending transversally to the extension surface 331 in the direction of the axis X 3 . This stop surface 332 limits the protrusion of the stopper 8 through the front face 11 of the body 1 . A second area is made up of a lip 35 that extends towards the socket opening 39 , inside the third area 36 defined by a socket surface 361 , extending from the lip to the bearing surface 34 , of which it defines the inner diameter D2.
The lip 35 is defined on its outer side by a slightly tapered lip surface 351 extending from the socket surface 361 to its extremity opposite the opening and forming an acute angle with the socket surface 361 . The lip 35 is defined on its inner side by a complex surface extending between the inner perimeter of the stop surface 332 and the inner perimeter of the lip surface 351 . This complex surface has two annular contours 352 with a trapezoidal section, extending radially towards the axis X 3 , flanking a groove 353 , also with a trapezoidal section. The contours 352 define the inner diameter D 3 of the lip. The diameter D 3 is approximately the diameter of the stem of a bicycle-type valve 202 (approximately 5.2 mm). Any thickness of the lip, measured transversally to the axis X 3 , is small relative to lengths of its inner and lip surfaces, measured axially. In particular, the thickness of the lip is significantly less than the thickness of the seal measured between its outer surface 32 and its socket surface 361 or between its outer surface 32 and its extension surface 331 . The lip is therefore very flexible, allowing it to deform more easily than the thicker parts of the seal.
The stopper 8 will now be described, with particular reference to FIGS. 6 and 1 . The hollow stopper has a hollow cylindrical guide 81 , with an outer diameter D 1 , allowing for the stopper to slide in the pipe 13 . The front end of the spring 9 is lodged inside the guide and is positioned transversally relative to the axis X 1 of the body 1 . The hollow stopper 8 also has a nose 82 , extending from the hollow guide 81 towards the opening 41 in the cover 4 . The nose 82 has channels 83 that open on one side onto the inside of the hollow guide 81 and on the other through a front surface of the nose. In the configuration in FIG. 1 , that is, with the pump not connected to any valve and the lever 6 being lowered, the lip 35 is located around the nose 82 of the stopper 8 .
It will also be noted that in the configuration in FIG. 1 , the pressurised air provided by the piston/cylinder assembly first travels through the channel 14 , passes up the pipe 13 and then enters the stopper 8 through the hollow guide 81 , entering the channels 83 to exit the hollow stopper in the socket 36 before being expelled from the pump through the openings 39 and then 41 , thus forming a circuit for the circulation of the air in the pump connector. The cover 4 is screwed to a head 16 on the housing 2 . It is therefore possible to adjust the distance between the cover and the axis X 7 of the pivot by screwing the cover 4 . This distance is advantageously chosen so that when the lever 6 is lowered, the body and the seal 3 are locked between the cam 61 and the cover 4 , whilst ensuring that the pressure exerted axially on the seal 3 is zero or low, i.e. the seal 3 is not deformed or slightly deformed. Thus, the contact between the front bearing surface 34 of the seal 3 and the cover forms a seal around the opening 41 in the cover 4 and the contact between the compression surface 31 of the seal 3 and the front face 11 of the body 1 forms a seal on it. Thus, even when the lever is lowered, the circuit is airtight along its length for the circulation of the air in the pump connector.
The operation of the pump connector 100 when it is connected to a car-type valve 201 will now be described with reference to FIGS. 3 to 6 . The car-type valve 201 is shown partly on the Figures. It is fitted onto a tyre for the inflation of the said tyre. It has a stem 211 that defines a passage 215 for the air between the outside of the tyre and the tyre. The car-type valve 201 has a valve flap (not shown) to prevent the deflation of the tyre through the passage. The car-type valve 201 has, along the axis of the stem, in the air passage, a pin 212 that is used to control the opening of the flap by pressing on one end 213 of the pin 212 , accessible from outside the stem. The stem 211 has a conical inner chamfer 214 around the passage 215 , at the end opening onto the outside of the tyre, that is, on the inner edge of this end.
As shown in FIG. 3 , when the stem 211 is placed in front of the connector 100 , the connector is in the position shown in FIG. 1 , with the lever 6 lowered. As shown in FIG. 4 , the stem 211 is then introduced along the axis X 1 through the openings 41 and then 39 into the socket 36 in the seal 3 . The stem fits between the lip 35 and the socket surface 361 , and the chamfer 214 presses against the lip surface 351 , which tends to push the lip 35 towards the axis X 3 of the seal, contracting and thus immobilising the nose 82 of the stopper 8 , whilst the front surface of the stopper 8 comes into contact with the end 213 of the pin 212 , which is pushed axially into the passage 215 . Thus, the imnmobilisation of the stopper allows for the pin 212 to be operated. The valve flap is thus open, connecting the inside of the tyre and the air circulation circuit 83 , 81 , 13 , 14 in the connector 100 . If the pressure in the tyre is greater than the pressure in the pump cylinder, a ball valve 15 between the circuit and the cylinder is held closed until the pressure in the cylinder becomes greater than the pressure in the tyre on pumping.
When the lever 6 is raised, moving the body 1 and compressing the seal 3 between the body 1 and the cover 4 , several approximately simultaneous actions occur. The first action is the reinforcement of the action of the stopper 8 on the end 213 of the pin by increasing the compression of the spring 9 between the base 131 , which moves with the body 1 , and the stopper 8 , which remains approximately immobile. By compressing the seal 3 , the conical front face 11 of the body 1 , pressing against the compression surface 31 of the seal, which is also conical, tends to deform the seal so that it contracts radially around its axis X 3 as well as axially. Thus, the second action is the radial and axial deformation of the lip 35 , gripped between the chamfer 214 and the nose 82 of the stopper 8 . It must be noted that the nose 82 has on its outer surface shapes that complement the shapes 352 , 353 of the complex surface of the lip 35 , which presses against it and deforms it. This thus ensures that the stopper 8 is held in place and forms a seal between the air circuit and the valve during inflation, i.e. the contours 352 interlock with complementary grooves on the outer surface 85 of the nose 82 and hold onto it, and the lip 35 , gripped between this outer surface 85 and the chamfer 214 , serves as a seal. By compressing the seal 3 , the third action is the contraction of the socket surface 361 around the stem 211 , ensuring that the valve is held firmly during inflation and forming another seal between the air circuit and the valve during inflation. This further seal may be sufficient, and the seal provided by the lip is in this case only supplementary.
At the end of inflation, to release the car-type valve 201 , the lever 6 must simply be lowered so that the seal elastically returns to its shape and the connector 100 is removed from the valve.
The operation of the pump connector 100 when it is connected to a bicycle-type valve 202 will now be described with reference to FIGS. 7 to 9 . The bicycle-type valve 202 is shown partly on the figures. It is fitted onto a tyre for the inflation of the said tyre. It comprises a stem 221 that defines a passage for the air between the outside of the tyre and the tyre. The bicycle-type valve 202 has a valve flap that prevents the deflation of the tyre through the passage. The bicycle-type valve 202 has along the axis of the stem, in the air passage, a pin 222 that is used, by its being pushed into the stem, to control the opening of the flap by pressing on one end 223 of the pin 222 , accessible from outside the stem. A nut 225 , screwed onto the pin, is used to lock the pin by pressing against the stem so that if the end 223 is pressed accidentally, the pin cannot control the opening of the valve flap, thus causing the accidental deflation of the tyre. The nut 225 must therefore be unscrewed to allow the air to circulate in the passage with a view to inflating the tyre. It must be noted that the nut is configured to allow for the air to pass between the passage in the stem 221 and the outside of the tyre when the pin is pushed in and the nut is pressing against the stem.
As shown in FIG. 7 , when the stem 221 is placed in front of the connector 100 , the connector is in the position in FIG. 1 , with the lever 6 lowered. As shown in FIG. 8 , the stem 221 is then introduced along the axis X 1 through the openings 41 and then 39 into the socket 36 in the seal 3 . The end 223 of the pin 222 comes into contact with the front surface of the stopper. As the stem 221 enters the socket 36 , the pin 222 is gradually pushed in so that the flap on the bicycle-type valve 202 is gradually opened. When the nut 225 presses against the stem 221 , the pin, locked in this way, is not pushed any further into the stem. Whilst the stem 221 continues to enter the socket 36 , and then beyond between the lip 35 on the seal 3 , the end 223 of the pin gradually pushes the stopper back into the pipe 13 , until the spring is completely compressed, thus stopping the entry of the stem 221 . The pump connector 100 is designed so that in this position, shown in FIGS. 8 and 9 , the stopper is in the pipe 13 , beyond the front surface 11 of the body 1 .
A new air circuit 13 , 14 is established in the connector 100 , placing the air inside the tyre in contact with the air inside the pipe 13 , through the nut 225 . If the pressure in the tyre is greater than the pressure in the pump cylinder, the ball valve 15 is held closed until the pressure in the cylinder becomes greater than the pressure in the tyre on pumping.
When the lever 6 is raised, moving the body 1 and compressing the seal 3 between the body 1 and the cover 4 , this allows for the lip to contract around the stem 221 of the bicycle-type valve, in particular through the action described above of the conical surfaces of the body 1 and the seal 3 .
The pump connector 100 is designed so that in this position, shown in FIG. 9 , the lip 35 contracts around a favourable area 226 of the stem 221 to seal it during inflation. In particular, it is ensured that the lip does not contract around the thread used to screw on a conventional flexible bicycle pump connector of the prior art. Preferably, the inner diameter D3 of the lip and the inner diameter of the area 222 must be approximately the same. When contracted in this way, the lip forms a seal between the pipe 13 and the bicycle-type valve 202 , as well as holding the valve in place, during inflation. The stopper 8 , still locked between the spring 9 and the end 223 of the pin 222 in the valve, is used to hold open the bicycle-type valve flap to allow the pressurised air provided by the bicycle pump to enter the tyre.
At the end of inflation, to release the bicycle-type valve 202 , the lever 6 must simply be lowered and the connector 100 removed from the valve.
It can thus be seen that the pump operator does not have to concern himself with the type of valve, car-type or bicycle-type, on the tyre. The pumping operation is the same whatever the type of valve. This operation successively involves the pushing of the valve into the pump connector, the raising of the lever, pumping, and finally the release of the valve by lowering the lever.
Of course, the invention is not limited to the examples described above, and numerous adjustments can be made to these examples without leaving the scope of the invention.
Such a connector is not limited to connection to car-type or bicycle-type valves of the types described above, but can also be fitted to other types of existing or future valves. In particular, the diameters D 1 , D 2 and D 3 can be different depending on the diameters of the valves to which the pump is to be connected. Nor is it limited to use as a pump connector on bicycle pumps alone.
Instead of mounting the connector on a piston/cylinder assembly on a manual pump, it can also be mounted directly on a flexible hose on a compressed air supply station such as those available at service stations.
The operating controls can also be made up of other means than a cam lever, such as for example a screw to push the body into the housing to a greater or lesser extent.
The seal may partly or fully consist of materials other than an elastomer material, and in particular a thermoplastic material or rubber.
It is possible for the cover not to be screwed onto the housing, but to form an integral part of it. | Connector ( 100 ) to automatically connect an inflation device to a valve, comprising a hollow stopper ( 8 ) to operate elements for opening the valve and an elastically deformable seal ( 3 ), characterised in that the seal has a lip ( 35 ) designed to:
immobilize the stopper during inflation, if the aforementioned valve is of a first type; or deform to form a seal around the valve during inflation if the aforementioned valve is of a second type. This connector is particularly suitable for fitting to a bicycle pump. | 5 |
RELATED APPLICATIONS
[0001] The present application claims priority to U.S. Provisional Patent Application No. 61/539,924 filed 2011-09-27, whose contents are incorporated by reference in their entirety.
FIELD OF THE INVENTION
[0002] The present invention is directed to the processing of syngas created from the processing of carbonaceous material.
BACKGROUND
[0003] A raw synthesis gas product, hereinafter called ‘unconditioned syngas’, is generated by the process of steam reforming, and may be characterized by a dirty mixture of gases and solids, comprised of carbon monoxide, hydrogen, carbon dioxide, methane, ethylene, ethane, acetylene, and a mixture of unreacted carbon and ash, commonly called ‘char’, as well as elutriated bed material particulates, and other trace contaminants, including but not limited to ammonia, hydrogen chloride, hydrogen cyanide, hydrogen sulfide, carbonyl sulfide, and trace metals. FIG. 28 presents a more complete list of components that may be found in unconditioned syngas.
[0004] Unconditioned syngas may also contain a variety of volatile organic compounds (VOC) or aromatics including benzene, toluene, phenol, styrene, xylene, and cresol, as well as semi-volatile organic compounds (SVOC) or polyaromatics, such as indene, indan, napthalene, methylnapthalene, acenapthylene, acenapthalene, anthracene, phenanthrene, (methyl-) anthracenes/phenanthrenes, pyrene/fluoranthene, methylpyrenes/benzofluorenes, chrysene, benz[a]anthracene, methylchrysenes, methylbenz[a]anthracenes, perylene, benzo[a]pyrene, dibenz[a,kl]anthracene, and dibenz[a,h]anthracene.
[0005] Syngas processing technology applications can generally be defined as industrial processing systems that accept a syngas source and produce or synthesize some thing from it. Normally, these can be categorized into systems that generate hydrogen, ethanol, mixed alcohols, methanol, dimethyl ether, chemicals or chemical intermediates (plastics, solvents, adhesives, fatty acids, acetic acid, carbon black, olefins, oxochemicals, ammonia, etc.), Fischer-Tropsch products (LPG, Naptha, Kerosene/diesel, lubricants, waxes), synthetic natural gas, or power (heat or electricity).
[0006] A plethora of syngas processing technologies exist, each converting syngas into some thing, and each possessing its own unique synthesis gas cleanliness requirement. For example, a Fischer-Tropsch (FT) catalytic synthesis processing technology requires more stringent cleanliness requirements when compared to a methanol synthesis application. This is because some FT cobalt catalysts are extremely sensitive to sulfur, resulting in deactivation, whereas sulfur does not pose a problem for some catalytic methanol applications. Therefore, a vast array of permutations or combinations of syngas clean-up operational sequence steps are possible to meet the economical and process intensive demands of synthesis gas conversion technologies.
SUMMARY OF THE INVENTION
[0007] In one aspect, the present invention is directed to a method of processing unconditioned syngas. The method comprises removing solids and semi-volatile organic compounds (SVOC) from the unconditioned syngas, then removing volatile organic compounds (VOC), and then removing at least one sulfur containing compound.
[0008] In another aspect, the present invention is directed to a system for processing unconditioned syngas. The system comprises means for removing solids and semi-volatile organic compounds (SVOC) from the unconditioned syngas, a compressor configured to receive and compress the resultant syngas stream, means for removing volatile organic compounds (VOC) from the compressed resultant syngas stream, and at least one bed configured to receive VOC-depleted syngas stream and remove at least one sulfur compound.
[0009] In yet another aspect, the present invention is directed to a method for removing solids and semi-volatile organic compounds (SVOC) from unconditioned syngas. The method includes (a) contacting the unconditioned syngas with a solvent and water to thereby form an intermediate SVOC-depleted syngas containing steam, and a first mixture comprising SVOC, solids, solvent and water; (b) removing steam from the intermediate SVOC-depleted syngas containing steam to form: (i) a first depleted syngas stream which has a reduced amount of SVOC relative to the unconditioned gas stream, and (ii) a second mixture comprising SVOC, solids, solvent and water; (c) separating the water within the second mixture based upon immiscibility so that the SVOC, solids and solvent collect together to form a third mixture above the water; (d) separating the solids from the SVOC and solvent in a vessel having at least one liquid phase candle filter such that the solids agglomerate on a surface of the candle filter and form a filter cake having density greater than that of water within the vessel; (e) backflushing the candle filter to loosen the filter cake so that the filter cake sinks into the water within the vessel; and (f) removing the filter cake from a bottom of the vessel.
[0010] In still another aspect, the present invention is directed to a system for removing solids and semi-volatile organic compounds (SVOC) from unconditioned syngas. The system includes: a venturi scrubber configured to receive the unconditioned syngas, solvent and water and output an intermediate SVOC-depleted syngas containing steam together with a first mixture comprising SVOC, solids, solvent and water; a char scrubber configured to receive the intermediate SVOC-depleted syngas containing steam and the first mixture, and separately output: (i) a first depleted syngas stream which has a reduced amount of SVOC relative to the unconditioned gas stream, and (ii) a second mixture comprising SVOC, solids, solvent and water; a decanter configured to receive the second mixture and separate the water within the second mixture based upon immiscibility so that the SVOC, solids and solvent collect together to form a third mixture above the water within the decanter, the decanter further configured to separately output the water and the third mixture; and a vessel arranged to receive the third mixture, the vessel having at least one liquid phase candle filter and a vessel bottom provided with a drain port; wherein: the candle filter is capable of operating so that: (i) the solids agglomerate on a surface of the candle filter and form a filter cake, and (ii) the SVOC and solvent are removed through the candle filter, and the drain port is suitable for removing filter cake therethrough.
[0011] The present invention is further directed to a system for processing unconditioned syngas which include the aforementioned system for removing solids and semi-volatile organic compounds (SVOC), in combination with various types of VOC-removal equipment and sulfur-removal equipment which operate under pressure.
[0012] These and other aspects of the present invention are described below in further detail.
BRIEF DESCRIPTION OF DRAWINGS
[0013] FIG. 1 —Syngas Clean-Up Step Flow Diagram
[0014] FIG. 1 A- 1 D—Syngas Clean-Up System
[0015] FIGS. 1 E- 1 F—Abbreviated Syngas Clean Up System and Process
[0016] FIG. 2 —Step B, Hydrocarbon Reforming Module
[0017] FIG. 3 —Step C, Syngas Cooling Module
[0018] FIG. 4 —Step D, Option 1, Block Process Flow Diagram for Solids & SVOC Removal
[0019] FIG. 5 —Step D, Solids & SVOC Removal Module
[0020] FIG. 6 —Step D, Option 1, Continuous Solvent Filtration & Filtrate Backflush Regeneration Module
[0021] FIG. 7 —Filtrate Backflush Regeneration Operation Process Flow Diagram
[0022] FIG. 8 —Step D, Option 1, Sequence Step Operation Flow Diagram
[0023] FIG. 9 —Step D, Option 2, Block Process Flow Diagram for Solids & SVOC Removal
[0024] FIG. 10 —Step D, Option 2, Sequence Step Operation Process Flow Diagram
[0025] FIG. 11 —SVOC Separation System, Option 1, SVOC Flash Separation Module
[0026] FIG. 12 —SVOC Separation System, Option 2, SVOC Sorptive Separation Module
[0027] FIG. 13 —Step E, Chlorine Removal Module
[0028] FIG. 14 —Step F, Sulfur Removal Module
[0029] FIG. 15 —Step G, Particulate Filtration Module
[0030] FIG. 16 —Step H, Syngas Compression Module
[0031] FIG. 17 —Step I, VOC Removal Module
[0032] FIG. 18 —Step I, VOC Separation System, Option 1, TSA/PSA System
[0033] FIG. 19 —Step I, VOC Separation System, Option 2, Fluidized Bed Adsorber System
[0034] FIG. 20 —Step J, Metal Removal Module
[0035] FIG. 21 —Step K, Ammonia Removal Module
[0036] FIG. 22 —Step L, Ammonia Polishing Module
[0037] FIG. 23 —Step M, Heat Addition Module
[0038] FIG. 24 —Step N, Carbonyl Sulfide Removal Module
[0039] FIG. 25 —Step O, Sulfur Polishing Module
[0040] FIG. 26 —Step P, Carbon Dioxide Removal Module
[0041] FIG. 27 —Steps Q, R, & S Heat Integration & Hydrocarbon Reforming Module
[0042] FIG. 28 —Typical Components within Unconditioned Syngas
[0043] FIG. 29 —Sequence Step Parameter & Contaminant Removal Efficiency
[0044] FIGS. 30 A- 30 F—List of Combinations of Steps Associated With Various Syngas Clean-Up Methods
DETAILED DESCRIPTION
[0045] FIG. 1 lists each syngas clean-up operational sequence step that may be included in an overall syngas cleaning process. As discussed below, not all steps need be performed in every implementation and so one or more of the steps may be optional.
[0046] The focus of the following text is to describe in detail the functionality, flexibility, and variability of each syngas clean-up process operational sequence step in communication with one another. It is further an object of the following text to elaborate upon the varying permutations of syngas clean-up process operational sequence steps to form an integrated syngas clean-up process.
[0047] Selection of a precise combination and/or permutation of steps and equipment may be important, as dictated by various criteria. Depending upon the process conditions involved, albeit be chemical and reactionary in nature, temperature, pressure, or presence or absence of a specific contaminate or component species, (such as water, for example) certain logical requirements and practical proprietary heuristics dictate where in the entire permutable sequence of unit operations a specific syngas clean-up operational sequence step may be placed.
[0048] A multitude of permutations of syngas operational sequence steps are possible to realize an overall integrated syngas clean-up process. Syngas contaminant tolerances, or cleanliness requirements of downstream syngas processing technologies, dictate how elaborate a given integrated syngas clean-up process must be.
[0049] The idea of a control volume is an extremely general concept used widely in the study and practice of chemical engineering. Control volumes may be used in applications that analyze physical systems by utilization of the laws of conservation of mass and energy. They may be employed during the analysis of input and output data of an arbitrary space, or region, usually being a chemical process, or a portion of a chemical process. They may be used to define process streams entering a single piece of chemical equipment that performs a certain task, or they may be used to define process streams entering a collection of equipment, and assets which work together to perform a certain task.
[0050] With respect to the surrounding text, a control volume is meaningful in terms of defining the boundaries of a particular syngas clean-up sequence step. With respect to the accompanied text, a sequence step may be defined as a member of an ordered list of events. These events may be arranged in a plethora of varying ways depending upon any number of requirements dictated by contaminant tolerances of any type of sygnas processing technology. Each sequence step is assigned a name corresponding to the problem is solves.
[0051] The arrangements of equipment contained within each control volume are the preferred ways of accomplishing each sequence step. Furthermore, all preferred embodiments are non-limiting in that any number of combinations of unit operations, equipment and assets, including pumping, piping, and instrumentation, may be used as an alternate. However, it has been our realization that the preferred embodiments that make up each sequence step are those which work best to realize contaminant removal efficiencies as described in FIG. 29 . Nonetheless, any types of unit operations or processes may be used within any control volume shown as long as it accomplishes the goal of that particular sequence step.
[0052] FIGS. 1A through 1D depict one embodiment of a system consistent with the steps shown in FIG. 1 to realize an overall integrated syngas clean-up process. The specific details of each control volume are elaborated upon in the accompanied text below.
[0053] FIG. 1A illustrates a Hydrocarbon Reforming Control Volume [B- 1 ] accepting an unconditioned syngas through a Sequence Step B Syngas Inlet [B-IN] and outputting a syngas of improved quality through a Sequence Step B Syngas Discharge [B-OUT]. Syngas quality improvement is defined below and is achieved through hydrocarbon reforming and/or cracking with the use of either partial oxidative, catalytic, or non-thermal non-catalytic systems or processes.
[0054] Syngas of improved quality is then routed to a Syngas Cooling Control Volume [C- 1 ] through a Sequence Step C Syngas Inlet [C-IN] which reduces the temperature of the syngas prior to outputting the cooled syngas through a Sequence Step C Syngas Discharge [C-OUT]. Any number of processes and unit operations may be employed to cool the syngas within this control volume and the objective of this process step is to reduce the temperature of the syngas prior to the removal of solids and semi-volatile organic compounds (SVOC) within the following sequence step.
[0055] Solids and SVOC are next removed from the unconditioned syngas within a Solids Removal & SVOC Removal Control Volume [D- 1 ]. A solids and SVOC laden Sequence Step D Syngas Inlet [D-IN] is provided to the control volume where the assets included therein remove solids and SVOC from the syngas to output a solids and SVOC-depleted Sequence Step D Syngas Discharge [D-OUT]. It is preferable to remove solids and SVOC utilizing the systems and methods as described below, however any type of systems and methods may be utilized within this control volume to accomplish the goal of the sequence step to remove solids and SVOC from syngas.
[0056] FIG. 1B illustrates the solids and SVOC-depleted Sequence Step D Syngas Discharge [D-OUT] being routed to a Chlorine Removal Control Volume [E- 1 ] which accepts through a chlorine laden Sequence Step E Syngas Inlet [E-IN] and outputs a chlorine depleted Sequence Step E Syngas Discharge [E-OUT]. It is preferable that chlorine is scrubbed from the syngas with the use of water, however any type of scrubbing liquid may be used, and in addition, any type of chlorine removal process or system may be employed to accomplish the goal of the sequence step to remove chlorine from syngas.
[0057] Syngas depleted of chlorine is then routed to a Sulfur Removal Control Volume [F- 1 ] which accepts as a sulfur laden Sequence Step F Syngas Inlet [F-IN], and outputs a sulfur-depleted Sequence Step F Syngas Discharge [F-OUT]. It is preferable that sulfur is scrubbed from the syngas with the use of a triazine hydrogen sulfide scavenger, however any type of scrubbing liquid may be used, and in addition, any type of sulfur removal process or system may be employed to accomplish the goal of the sequence step to remove sulfur from syngas.
[0058] Syngas depleted of sulfur is then routed to a Particulate Filtration Control Volume [G- 1 ] which accepts as a particulate laden Sequence Step G Syngas Inlet [G-IN], and outputting a particulate depleted Sequence Step G Syngas Discharge [G-OUT]. It is desirable to have this sequence step in place immediately prior to the compression step so as to provide a final separation of any solids that may carry over, or become elutriated, during any intermittent operational upset within the upstream solids removal unit operations.
[0059] Syngas is then routed to a Syngas Compression [H] step wherein a Syngas Compressor accepts as a Sequence Step H Syngas Inlet [H-IN], and outputs a Sequence Step H Syngas Discharge [H-OUT]. The following described sequence steps and processes illustrated in FIGS. 1C through 1D primarily operate at a pressure higher than the preceding described sequence steps, relatively, since the compressor elevates the pressure of the syngas so that the outlet syngas is at a higher pressure in relation to the inlet syngas pressure.
[0060] As seen in FIG. 1C , compressed syngas is then routed to a Volatile Organic Compounds (VOC) Removal Control Volume [I- 1 ], which accepts as a VOC laden Sequence Step I Syngas Inlet [I-IN], and outputs a VOC-depleted Sequence Step I Syngas Discharge [I-OUT]. It is preferable that VOC is removed with the use of pressure swing and temperature swing adsorption and desorption methods and systems utilizing either microchannel heat exchangers, or pressure or temperature swing adsorption and desorption methods and systems utilizing fixed beds, or even utilizing fluidized bed systems and methods in which syngas fluidizes a sorbent material to remove VOC within the syngas, and in addition, any type of VOC removal process or system may be employed to accomplish the goal of the sequence step to remove VOC from syngas.
[0061] VOC-depleted syngas is the routed to a Metal Removal Control Volume [J- 1 ] which accepts through a metal laden Sequence Step J Syngas Inlet [J-IN], and outputs a metal depleted Sequence Step J Syngas Discharge [J-OUT]. It is preferable that metals are adsorbed from the syngas with the use fixed bed systems and methods utilizing suitable adsorbent materials, however absorption may employed instead, and in addition, any type of metals removal process or system may be employed to accomplish the goal of the sequence step to remove metal from syngas.
[0062] Syngas depleted of metals is then routed to an Ammonia Removal Control Volume [K- 1 ] which accepts as an ammonia laden Sequence Step K Syngas Inlet [K-IN], and outputs an ammonia-depleted Sequence Step K Syngas Discharge [K-OUT]. It is preferable that ammonia is scrubbed from the syngas with the use of water, however any type of scrubbing liquid may be used, and in addition any type of ammonia removal system may be employed to accomplish the goal of the sequence step to remove ammonia from syngas.
[0063] Syngas depleted of ammonia is then routed to an Ammonia Polishing Control Volume [L- 1 ] which accepts as a Sequence Step L Syngas Inlet [L-IN], and outputs Sequence Step L Syngas Discharge [L-OUT]. It is preferable that ammonia is polished from the syngas using fixed bed adsorption systems and methods; however any type of ammonia polishing system may be employed to accomplish the goal of the sequence step to polish ammonia from syngas.
[0064] FIG. 1D displays a series of sequence steps to be performed to remove sulfur containing compounds. Syngas polished of ammonia is routed to a Heat Addition Control Volume [M- 1 ], which accepts through a Sequence Step M Syngas Inlet [M-IN], and outputs a Sequence Step M Syngas Discharge [M-OUT]. The goal of this control volume is to elevate the temperature of the syngas prior to removal of sulfur containing compounds.
[0065] Syngas at an elevated temperature is then routed to a Carbonyl Sulfide Removal Control Volume [N- 1 ] which accepts a carbonyl sulfide laden Sequence Step N Syngas Inlet [N-IN], and outputs a sulfur-depleted Sequence Step N Syngas Discharge [N-OUT]. It is preferred to accomplish the goals of this sequence step with the utilization of a packed bed of an alumina based material which allows for the hydrolysis of carbonyl sulfide into carbon dioxide and hydrogen sulfide, however any type of carbonyl sulfide removal system or method, such as adsorption or absorption type systems, may be employed to accomplish the goal of the sequence step to remove carbonyl sulfide from syngas.
[0066] Sulfur-depleted syngas is then routed to a final Sulfur Polishing Control Volume [O- 1 ] which accepts as a Sequence Step O Syngas Inlet [O-IN], and outputs through a Sequence Step O Syngas Discharge [O-OUT]. It is preferable that sulfur is polished from the syngas using fixed bed adsorption systems and methods; however any type of sulfur polishing system may be employed to accomplish the goal of the sequence step to polish sulfur from syngas.
[0067] Sulfur-depleted syngas is then routed to a Carbon Dioxide Removal Control Volume [P- 1 ], which accepts through a carbon dioxide laden Sequence Step P Syngas Inlet [P-IN], and outputting a carbon dioxide depleted Sequence Step P Syngas Discharge [P-OUT]. Membrane based processes are the preferred system utilized to remove carbon dioxide from syngas, however other alternate systems and methods may be utilized to accomplish the goals of this sequence step, not limited to adsorption or absorption based carbon dioxide removal systems and processes. In a further embodiment, carbon dioxide may be reduced within this sequence step by use of a carbon dioxide electrolyzer.
[0068] FIG. 1E represents a preferred embodiment where an unconditioned syngas is provided to a Solids Removal & SVOC Removal Control Volume [D- 1 ] which accepts unconditioned syngas through a solids and SVOC laden Sequence Step D Syngas Inlet [D-IN] and removes solids and SVOC from the unconditioned syngas to form a first depleted syngas stream thereby discharging through a solids and SVOC-depleted Sequence Step D Syngas Discharge [D-OUT]. The first depleted syngas stream has a reduced amount of solids and SVOC relative to the unconditioned syngas.
[0069] The first depleted syngas stream is then routed to a Volatile Organic Compounds (VOC) Removal Control Volume [I- 1 ], which accepts as a VOC laden Sequence Step I Syngas Inlet [I-IN], and removes volatile organic compounds (VOC) from the first depleted syngas stream to form a second depleted syngas stream which has a reduced amount of VOC relative to the first depleted syngas stream thereby outputting through a VOC-depleted Sequence Step I Syngas Discharge [I-OUT].
[0070] The second depleted syngas stream is then routed to a Carbonyl Sulfide Removal Control Volume [N- 1 ] which accepts as a carbonyl sulfide laden Sequence Step N Syngas Inlet [N-IN], and removes at least one sulfur containing compound from the second depleted syngas stream to produce a sulfur-depleted syngas stream which has a reduced sulfur amount of sulfur relative to the second depleted syngas stream thereby outputting as a sulfur-depleted Sequence Step N Syngas Discharge [N-OUT].
[0071] The sulfur-depleted syngas stream is then routed to a final Sulfur Polishing Control Volume [O- 1 ] which accepts as a Sequence Step O Syngas Inlet [O-IN], and provides an additional sulfur polishing step to reduce total sulfur content to less than 100 part-per billion thereby discharging through a Sequence Step O Syngas Discharge [O-OUT].
[0072] FIG. 1F represents a preferred embodiment where an unconditioned syngas is provided to a Solids Removal & SVOC Removal Control Volume [D- 1 ] which accepts unconditioned syngas through a solids and SVOC laden Sequence Step D Syngas Inlet [D-IN] and removes solids and SVOC from the unconditioned syngas to form a first depleted syngas stream thereby discharging through a solids and SVOC-depleted Sequence Step D Syngas Discharge [D-OUT]. The first depleted syngas stream has a reduced amount of solids and SVOC relative to the unconditioned syngas.
[0073] The first depleted syngas stream is then routed to a Volatile Organic Compounds (VOC) Removal Control Volume [I- 1 ], which accepts as a VOC laden Sequence Step I Syngas Inlet [I-IN], and removes volatile organic compounds (VOC) from the first depleted syngas stream to form a second depleted syngas stream which has a reduced amount of VOC relative to the first depleted syngas stream thereby outputting through a VOC-depleted Sequence Step I Syngas Discharge [I-OUT].
[0074] The second depleted syngas stream is then routed to a final Sulfur Polishing Control Volume [O- 1 ] which accepts as a Sequence Step O Syngas Inlet [O-IN], and provides an additional sulfur polishing step to generate a sulfur-depleted syngas stream which has a reduced sulfur amount of sulfur relative to the second depleted syngas stream thereby discharging through a Sequence Step O Syngas Discharge [O-OUT].
Sequence Step B, Hydrocarbon Reforming [B]
[0075] FIG. 2 illustrates Sequence Step B, Hydrocarbon Reforming [B]. Hydrocarbon Reforming Control Volume [B- 1 ] encapsulates the preferred arrangement of equipment and assets that work together to provide a method for improving syngas quality by reforming and/or cracking one or more undesirable syngas constituents into desirable syngas constituents.
[0076] As used herein the term “desirable syngas constituents” or “favorable syngas constituents” or variants thereof refer to hydrogen (H 2 ) and carbon monoxide (CO).
[0077] As used herein the term “undesirable syngas constituents” refer to any constituents present in syngas other than hydrogen (H 2 ) and carbon monoxide (CO), including, but not limited to, carbon dioxide (CO2), hydrocarbons, VOC, SVOC, nitrogen containing compounds, sulfur containing compounds, as well as other impurities that are present in the feedstock that can form during thermochemical syngas generation processes.
[0078] As used herein the term “hydrocarbon” refers to organic compounds of hydrogen and carbon, CxHy. These may include, but not limited to methane (CH 4 ), ethane (C 2 H 6 ), ethylene (C 2 H 4 ), propane (C 3 H 8 ), benzene (C 6 H 6 ), etc. Hydrocarbons include VOC and SVOC.
[0079] As used herein “improved syngas quality” or variants thereof refer to a syngas where at least one undesirable syngas constituent is reformed and/or cracked into at least one desirable syngas constituent.
[0080] As used herein the term “cracking” or “cracked” or variations thereof mean that undesirable syngas constituents, including hydrocarbons, SVOC, and/or VOC, are reacted with a suitable catalyst and/or in a partial oxidative environment and/or in a non-thermal non-catalytic plasma environment, to provide chemical species comprised of decreased molecular weights. For example, raw syngas that may contain propane (C 3 H 8 ), having a molecular weight of 44 lb/mol, may be cracked into compounds comprised of lesser molecular weights, for example, methane (CH 4 ) and ethylene (C 2 H 4 ), both having lesser molecular weights than that of propane, being 16 lb/mol and 28 lb/mol, respectively.
[0081] As used herein the term “reforming” or “reformation” or variations thereof mean that undesirable syngas constituents, including hydrocarbons, SVOC, and/or VOC, are converted into desirable syngas constituents. For example, in the presence of an oxidant and a suitable catalyst and/or in a partial oxidative environment and/or in a non-thermal non-catalytic plasma environment, methane (CH 4 ) can be reformed into carbon monoxide (CO) and hydrogen (H 2 ).
[0082] Unconditioned syngas may be transferred from a Syngas Generation [A] system, preferably a biomass steam reforming system (not shown), and routed through Sequence Step B Syngas Inlet [B-IN] into a Hydrocarbon Reforming Control Volume [B- 1 ], which produces a Sequence Step B Syngas Discharge [B-OUT].
[0083] This Hydrocarbon Reformer [ 8000 ] is preferably of a non-thermal, non-catalytic, cold plasma gliding-arc type, however, partial oxidation, and/or catalytic systems, or combinations thereof, may be employed to accomplish the sequence step objective of hydrocarbon reforming and/or cracking for syngas quality improvement. The Hydrocarbon Reformer generates a syngas or improved quality and depleted of VOC, SVOC, and other less desirable constituents, including, carbon dioxide, methane, ethylene, ethane, and acetylene, which may then be routed from the reformer through a Sequence Step B Syngas Discharge [B-OUT].
[0084] Additives [ 2 ], including solids possessing low ionization potential, not only including alkali metals, preferably sodium compounds or potassium compounds or mixtures thereof, may be provided to the Hydrocarbon Reformer. Utilization of these additives serves the purpose to increase the ionization energy in the cold plasma reaction zone within the Hydrocarbon Reformer, and thus aiding the decomposition of SVOC, and VOC, along with the less desirable syngas constituents, into favorable constituents including carbon monoxide and hydrogen. The presence of the additives within the Hydrocarbon Reformer favorably alters the electron density within the cold plasma arc reaction zone. This in turn enhances the thermochemical and electrochemical properties within the plasma reaction zone resultantly increasing the efficiency of the Hydrocarbon Reformer to reform and/or crack the VOC, SVOC, and other less desirable constituents into carbon monoxide and hydrogen.
[0085] An oxidant source [ 4 ], including, but not limited to, carbon dioxide, steam, air, or oxygen, may be made available to the Hydrocarbon Reformer to increase the reforming and/or cracking efficiency to promote production of carbon monoxide and hydrogen.
[0086] A gaseous hydrocarbon source [ 6 ] may be made available to the Hydrocarbon Reformer and may include, natural gas, syngas, refinery offgases, methanol, ethanol, petroleum, methane, ethane, propane, butane, hexane, benzene, toluene, xylene, or even waxes or low melting solids such as paraffin wax and naphthalene.
Sequence Step C, Syngas Cooling [C]
[0087] FIG. 3 illustrates Sequence Step C, Syngas Cooling [C], wherein Syngas Cooling Control Volume [C- 1 ] accepts a Sequence Step C Syngas Inlet [C-IN] and outputs a Sequence Step C Syngas Discharge [C-OUT].
[0088] Syngas may be routed through a Sequence Step C Syngas Inlet [C-IN], to a Heat Recovery Steam Generator (HRSG) Superheater [ 8025 ], where heat is indirectly removed from the syngas. The HRSG Superheater is preferably a shell and tube type heat exchanger, with the hot syngas traveling through the tube-side indirectly contacting steam which is located on the shell-side. Heat is transferred from the syngas traveling on the equipment's tube-side to the saturated steam that flows through the heat exchanger shell-side, thus generating a source of superheated steam [ 8 ] discharged from the shell-side of the Heat Recovery Steam Generator (HRSG) Superheater.
[0089] Syngas is transferred from the HRSG Superheater to the Heat Recovery Steam Generator (HRSG) [ 8050 ] through HRSG transfer line [ 10 ] where the syngas is further cooled prior to being discharged from the HRSG through Sequence Step C Syngas Discharge [C-OUT]. The HRSG is preferably a shell and tube type heat exchanger, with the syngas on the tube-side and water on the shell-side. Water [ 12 ] is introduced to a HRSG lower shell-side inlet and used as the heat transfer fluid to remove thermal energy from the syngas. A steam and water mixture [ 14 ] is generated in the shell-side of the HRSG and transferred to the Steam Drum [ 8075 ]. The Steam Drum is operated under pressure control with a pressure transmitter [ 16 ] acting in communication with a pressure control valve [ 18 ] located on the HRSG Superheater shell-side superheated steam [ 8 ] discharge line. When pressure control valve [ 18 ] opens and releases pressure on automatic pressure control, to maintain a steady pressure in the Steam Drum, saturated steam is transferred to the HRSG Superheater through saturated steam transfer line [ 20 ], where steam indirectly contacts the syngas flowing through the HRSG Superheater. The Steam Drum is operated under level control where a level transmitter [ 22 ] located on the vessel acts in communication with a level control valve [ 24 ] located on a water supply line [ 26 ] to provide water to maintain sufficient level in the Steam Drum to allow recirculation of water through the shell-side of the HRSG. A continuous purge of water flows from the Steam Drum through a steam drum continuous blowdown line [ 28 ] to regulate the concentration of suspended and total dissolved solids within the volume of water contained within the Steam Drum.
[0090] Any type of heat exchange system may be used to achieve the syngas cooling functionality prescribed in Sequence Step C. One single heat exchanger may be used, or more than one may be used. Saturated steam may be generated, as opposed to superheated steam. A forced recirculation HRSG cooling water loop may be used as opposed to the disclosed natural thermosiphon configuration.
Sequence Step D, Solids Removal & SVOC Removal [D]
Venturi Scrubber
[0091] FIG. 4 illustrates Sequence Step D, Solids Removal & SVOC Removal [D], wherein Solids Removal & SVOC Removal Control Volume [D- 1 ] accepts an unconditioned syngas through a Solids & SVOC laden Sequence Step D Syngas Inlet [D-IN], and outputs a first depleted syngas stream, which has a reduced amount of solids and SVOC relative to the unconditioned syngas, through a Solids & SVOC-depleted Sequence Step D Syngas Discharge [D-OUT].
[0092] Although any commercially available system capable of removing solids and SVOC from syngas may be employed, the specific combination and configuration of equipment and assets, and methods of operation, disclosed herein, indicate the preferred system to be utilized.
[0093] Two separate block process flow drawing configurations for Solids Removal & SVOC Removal Control Volume [D- 1 ] are disclosed in the accompanying text. These are Option 1 and Option 2 as illustrated in FIG. 4 , and FIG. 9 , respectively. FIG. 5 together with FIG. 6 clarify details of preferred Option 1 of Sequence Step D.
[0094] Cooled unconditioned syngas is routed to a wetted throat Venturi Scrubber [ 8100 ] through Sequence Step D Syngas Inlet [D-IN]. The Venturi Scrubber operates at a temperature below the SVOC condensation temperature and below the dew-point of the excess steam contained within the syngas therefore condensing said SVOC and excess steam out into a liquid phase. Solid char particulates entrained within the syngas come into contact with water provided by a Venturi Scrubber recirculation water line [ 30 ], and solvent provided by a Venturi Scrubber recirculation solvent line [ 32 ], at the divergent section of the Venturi Scrubber and said particulates act as a nuclei for excess steam condensation and are displaced from the vapor phase and into the liquid phase.
Char Scrubber
[0095] An intermediate SVOC-depleted syngas containing steam together with a first mixture comprising SVOC, solids, solvent and water, is routed to the lower section of the Char Scrubber [ 8125 ] via a Venturi Scrubber to Char Scrubber transfer conduit [ 34 ]. The Char Scrubber serves as an entrainment separator for the Venturi Scrubber and is configured to receive the intermediate SVOC-depleted syngas containing steam and the first mixture, and separately output a first depleted syngas stream and a second mixture comprising SVOC, solids, solvent and water.
[0096] The Char Scrubber, is preferably a vertically oriented cylindrical, or rectangular, pressure vessel having a lower section, and an upper section, along with a central section that contains a quantity of packed media either comprising raschig rings, pall rings, berl saddles, intalox packing, metal structured grid packing, hollow spherical packing, high performance thermoplastic packing, structured packing, synthetic woven fabric, or ceramic packing, or the like, wherein media is supported upon a suitable support grid system commonplace to industrial chemical equipment systems. The upper section of the scrubber preferably contains a demister to enhance the removal of liquid droplets entrained in a vapor stream and to minimize carry-over losses of the sorption liquid. This demister is also positioned above the scrubber spray nozzle system [ 36 ], comprised of a plurality of spray nozzles, or spray balls, that introduce and substantially equally distribute the scrubbing absorption liquid to the scrubber onto the scrubber's central packing section so it may gravity-flow down through the scrubber central section.
[0097] As the syngas passes up through the internal packing of the Char Scrubber, excess steam within the syngas comes into intimate contact with water [ 38 ] and solvent [ 40 ], which are cooled prior to being introduced to the upper section of the Char Scrubber through the scrubber spray nozzle system. Steam is condensed into a liquid phase before being discharged from the Char Scrubber via the Char Scrubber underflow downcomer [ 42 ].
[0098] Intimate gas to liquid contact within the Char Scrubber allows for the solvent to both, absorb SVOC from the syngas, and enable carbon contained within the char, comprised of a carbon and ash mixture, to become oleophilic and hydrophobic permitting said carbon to become suspended within the solvent before both the solvent and carbon are discharged from the Char
[0000] Scrubber through the Char Scrubber Underflow Downcomer [ 42 ].
[0099] A Char Scrubber Heat Exchanger [ 8150 ] is installed in the common water recirculation line [ 44 ], and is preferably of the shell and tube type heat exchanger, wherein syngas steam condensate transferred to scrubbing operations resides on the tube-side, and a cooling water supply [ 46 ], and a cooling water return [ 48 ], communicate with the shell-side of the heat exchanger to fulfill the heat transfer requirements necessary to indirectly remove heat from the tube-side steam condensate recirculation scrubbing liquid.
Solvent Selection Definition
[0100] Where the end syngas user is a FT synthesis reactor, the preferred scrubbing solvent is Medium Fraction Fischer-Tropsch Liquid (MFFTL) generated from the downstream FT catalytic synthesis process, however other Fischer-Tropsch products may be used. The ability to generate a valuable scrubbing solvent on-site provides a financial benefit due to operational self-sufficiency thus improving plant operating costs since the facility need not rely upon an outside vendor to furnish the sorption liquid.
[0101] Where the end syngas processing technology is a fuels, power, or chemicals production application, the preferred scrubbing solvent is a degreaser solvent, or a biodegradable, non-toxic, and environmentally safe, industrial cleaning solvent for biodiesel residue, such as BioSol TS 170™, marketed by Evergreen Solutions. Nonetheless, many types of hydrophilic solvents may be used, including, but not limited to, glycerol, rapeseed methyl ester, biodiesel, canola oil, vegetable oil, corn oil, castor oil, or soy oil, listed in decreasing preference.
Immiscibility Definition
[0102] It is to be understood that the water and solvent are immiscible in that they are incapable of being mixed to form a homogeneous liquid. The solvent phase is relatively less dense than the water phase allowing the solvent phase to float on top of the water phase. It is also to be understood that the solvent possesses a relatively greater affinity for the unreacted carbon particulate than the water. This is partly due to the solvent possessing an adhesive tension relative to the carbon solid particulate exceeding that of water. It is also to be understood that the carbon separates immediately and substantially completely from the water phase and floats on the surface as an unagglomerated fine solid particulate substance leaving a clear water phase below.
Continuous Candle Filter Decanter
[0103] A Continuous Candle Filter Decanter [ 8175 ] may be utilized to accept syngas excess steam condensate, solvent, and carbon and ash from the Char Scrubber underflow downcomer [ 42 ]. The Continuous Candle Filter Decanter is configured to receive the second mixture ash from the Char Scrubber underflow downcomer [ 42 ] and separate the water within the second mixture based upon immiscibility so that the SVOC, solids and solvent collect together to form a third mixture above the water within the decanter vessel, the decanter vessel further configured to separately output the water and the third mixture.
[0104] The Continuous Candle Filter Decanter is comprised of an upright tank [ 50 ], made up of two parts, a hollow cylindrical, or rectangular, central section [ 52 ] with a closed dome shaped top [ 54 ]. It has one or more conical lower sections [ 56 a & 56 b ] each terminating at the bottom in a drain port with a suitable drain valve [ 58 a & 58 b ] and a drain line [ 60 a & 60 b ]. These drain lines may be connected to a separate commercially available Filter Cake Liquid Removal System [ 8225 ], preferably of a mechanical pressure filter-belt press, or any similar device that exerts a mechanical pressure on a liquid laden sludge like filter cake substance to separate liquid therefrom.
[0105] A vertical water underflow weir [ 62 ] extends downward from the dome shaped top of the upright tank and is spaced away from and cooperates with the upright vertical housing wall [ 64 ] of the hollow center section to provide an annular passageway [ 66 ] therebetween for passage of the syngas steam condensate water phase into a common water header [ 68 ] taken from various water take-off nozzles [ 70 a & 70 b ], circumferentially positioned around the upper portion of the outer annular passageway. Water may be routed to the water recirculation pump [ 72 ] and transferred to the Char Scrubber and Venturi Scrubber. Water take-off nozzles may be positioned at various points about the upright vertical housing walls, or water may be pumped from various points located on closed dome shaped top. Only two water take-off nozzles are shown for simplicity, however many more are preferred, usually one take-off point for each candle filter bundle, wherein a commercial system may contain about 4 candle filter bundles.
[0106] The vertical water underflow weir is comprised of an upright annular wall that terminates at a height within the pressure vessel deep enough to provide an inner solvent chamber [ 74 ] intended to contain the solvent used for recirculation in the scrubbing system. The solvent chamber is positioned in between the Char Scrubber underflow downcomer [ 42 ] and the vertical underflow weir [ 62 ]. The solvent and water interface layer is contained within the inner solvent chamber [ 76 ], and therefore the solvent and water interface rag-layer [ 78 ] will also be restricted to the inner solvent chamber.
[0107] It is to be understood that the ‘rag-layer’ describes the region wherein the solvent and water interface resides, also the location where unagglomerated carbon may accumulate based on the fact that carbon is more dense than solvent, thus sinking to the bottom of the solvent phase, but being less dense than water, allowing it to float on top of the water phase, or at the water and solvent interface layer.
[0108] The Char Scrubber underflow downcomer extends from the lower section of the Char Scrubber and is disposed within the inner solvent chamber terminating at a height within the solvent chamber at a vertical elevation relatively higher than, and above, the vertical weir underflow height. It is preferential to operate the system so that the solvent and water interface rag-layer resides at the region in the solvent chamber where the downcomer terminates within the solvent chamber.
[0109] The inner solvent chamber, housed within the Continuous Candle Filter Decanter's cylindrical center section, may contain one or more filter bundles [ 80 a & 80 b ] containing a plurality of vertically disposed candle filter elements [ 82 ]. Preferably the elements are of the type which possess a perforated metal support core covered with a replaceable filter cloth, or synonymously termed filter-sock, of woven Teflon cloth with approximate 5-micron pore openings. During filtration, the filter cloth forms a ridged-type structure around the perforated metal core of the filter element and, thus ensuring good adherence of the filter cake during the filtration phase. Filtrate solvent is conveyed through the full-length of each individual candle filter element to the filter bundle common register [ 84 a & 84 b ] and to a filtrate removal conduit [ 86 a & 86 b ]. Only two candle filter bundles are shown in the figure for simplicity. Each filter element is closed at the bottom and allows for only circumferential transference of liquid through the filter sock into the perforations in the metal filter element support core.
[0110] A filtrate process pump [ 88 ], located on the common filtrate suction header [ 90 ], sucks solvent from the inner solvent chamber, through each filter element [ 82 ], of each filter bundle [ 80 a & 80 b ], through each filter bundle filtrate removal conduit [ 86 a & 86 b ] and filtrate register valve [ 92 a & 92 b ], and transfers it via [ 94 ] to an optional SVOC Separation System Control Volume [SVOC- 1 ] where SVOC is removed and an SVOC-depleted solvent is transferred to the Venturi Scrubber and Char Scrubber common solvent recirculation line [ 96 ].
[0111] Pressure transmitters [ 98 a & 98 b ] are installed on each filtrate removal conduit and may be used to monitor the differential pressure across each filter bundle in relation to the filter housing pressure provided by a similar pressure transmitter [ 100 ] located on the vertical housing. In-line flow indicating sight glasses [ 102 a & 102 b ] are installed on each filtrate removal conduit so that a plant operator may visually see the clarity of the filtrate to determine if any candle filter sock element has been ruptured and needs repair.
Backflush System
[0112] Filtrate Backflush Buffer Tank [ 8200 ] accepts SVOC-depleted filtrate solvent from the SVOC-depleted solvent transfer line [ 104 ], discharged from the SVOC Separation System. The tank is positioned in communication with the SVOC-depleted solvent transfer line [ 104 ] and preferably is installed in a vertical orientation relative to it so that solvent may flow via gravity into the tank. The Filtrate Backflush Buffer Tank is equipped with a level transmitter [ 106 ] that acts in communication with an solvent supply level control valve [ 108 ] located on a solvent supply line [ 110 ] which transfers fresh solvent to the system, either to the Filtrate Backflush Buffer Tank or to the Char Scrubber underflow downcomer (not shown).
[0113] The solvent backflush pump [ 112 ] accepts SVOC-depleted filtrate solvent from the Filtrate Backflush Buffer Tank through filtrate transfer conduit [ 114 ] and recirculates the solvent back to the Filtrate Backflush Buffer Tank through backflush tank recirculation line [ 116 ]. A restriction orifice [ 118 ], or similar pressure letdown device, such as an iris-type adjustable orifice valve, is located in-line to create a high pressure recirculation reservoir within the backflush tank recirculation line [ 116 ], and its connected piping network, to accommodate backflushing of the candle filter bundles.
Candle Filter Operation Philosophy
[0114] The best mode of operation for realizing a continuous filtrate stream encompasses operating the filtration system in a manner which allows for periodic backflushing of the filter element cloth surface in-situ by reversing the flow of liquid scrubbing solvent filtrate through the filter elements. The backwashing dislodges any accumulated filter cake allowing it to sink to the bottom of the conical section of the filter housing for removal of the system as a thick, paste-like, filter cake substance. Experimental results have consistently and repeatedly shown that regeneration of the filter elements to realize sustainable and continuous operation of the filter coincides with utilizing SVOC-depleted filtrate solvent as the backflush filter liquid. However the system will function as intended while utilizing alternate mediums to cleanse filter element surfaces, such as SVOC laden filtrate solvent, syngas steam condensate, or a vapor source, such as inert nitrogen or carbon dioxide.
[0115] It is preferred to utilize differential pressure across a filter bundle as the main variable to determine when to undergo a back flushing cycle, as opposed to using manual predetermined periodic time duration intervals, or using the reduction in flow through the filter bundles as the variable dictating when to commence filter back flushing, (synonymously termed ‘filter cleaning’, or ‘filter backwashing’, ‘in-situ filter cleaning’, or ‘filter surface in-situ regeneration’). This is because experimental results have shown that a filter bundle differential pressure between 6 and 10 PSI is commensurate with preferable cake thickness of 20 to 35 millimeters. In contrast, using manual predetermined periodic time duration intervals as the sole mechanism to determine when to commence filter cleaning, often results in operational impairment, in that ‘cake bridging’ more readily occurs. ‘Cake bridging’ is well known in the art of filtration. It may be described as a large mass of agglomerated suspended solids filling the spaces between the filter elements and thus posing a challenge to regenerate in-situ, frequently requiring process interruption for physical cleaning and removal of the heavy, gelatinous filter cake.
[0116] In-situ filter cleaning may be accomplished by reversing the flow of liquid through the filter element thereby dislodging filter cake from the cloth surface thus allowing it to sink to the bottom of the water phase within the lower filter chamber conical section. This affords operations the luxury of minimizing losses of valuable solvent while draining the filter cake from the system.
Candle Filter Operating Procedure
[0117] FIG. 7 depicts the preferred operating procedure for continuous filtration of suspended particulate solids from SVOC laden scrubbing solvent. Filtration [step 950 ] cooperates with the cyclic-batch filter in-situ cleaning steps of: filter bundle isolation [step 952 ]; filtrate backflush [step 954 ]; filter cake sedimentation [step 956 ]; filter cake discharge start [step 958 ]; filter cake discharge end [step 960 ]; and filtration restart preparation [step 962 ].
[0118] In step 950 , (filtration), filtration proceeds and the filter bundle pressure drop is monitored. As a filtration cycle progresses, solids are deposited onto the surface of each filter element and adhere to its surface until a nominal target differential pressure drop between around 6 to 10 PSI is attained, which is proportionate to a predetermined thickness of 20 to 35 millimeters. If the filter bundle pressure drop is lower than the nominal target differential pressure drop, the filtering cycle continues until the nominal target differential pressure drop is reached. When a filter bundle has reached its nominal target differential pressure drop, a filter cleaning cycle will commence, which begins with step 952 (filter bundle isolation). In addition to FIG. 7 , the sequential steps encompassing filtration and filter cleaning can be further illuminated by using FIG. 6 , which visually indicate some of the valve sequencing involved, as indicated by open and closed valve positions, illustrated by ‘non-darkened-in valves’ and ‘darkened-in valves’, respectively, of filtrate register valve [ 92 a & 92 b ], backflush filtrate regen valves [ 120 a & 120 b ] (located on respective filtrate backflush regen conduits [ 122 a & 122 b ]), as well as filter cake drain valves [ 58 a & 58 b ] located on each lower conical section. FIG. 6 , indicates filtrate register valve 92 a open and 92 b closed. It also shows backflush filtrate regen valves 120 a closed and 120 b open. FIG. 6 further depicts filter cake drain valves 58 b open and 58 a closed. It should be understood that these valves probably will never actually be opened at the same time; FIG. 6 , together with FIG. 7 , offer insight to the spirit of the operation, to clarify the preferred operating philosophy, and to provide the reader with a genuine appreciation for the sequencing involved.
[0119] When a nominal target pressure drop across a filter bundle is attained, the filter cake material must be dislodged from filter elements of a given filter bundle, and thus step 952 (filter bundle isolation) proceeds, which involves isolating the relevant filter bundle by closing the filtrate register valve 92 b to stop filtration on that given filter bundle. Once the filtrate register valve has been closed, to isolate the filter bundle that exhibits a pressure drop higher or equal to a nominal target pressure drop, step 954 may proceed. Step 954 , (filtrate backflush), involves transferring filtrate solvent from the pressurized recirculation loop [ 116 ], provided by the solvent backflush pump [ 112 ], through the relevant filtrate back-flush regen conduit [ 122 b ], injected though the filtrate regen valve [ 120 b ] where the solvent then countercurrently enters the filter bundle filtrate removal conduit [ 86 b ] and is transferred to the filter elements in need of regeneration.
[0120] It is to be understood that the operating discharge pressure of the solvent backflush pump [ 116 ], that required for the filtrate to be transferred countercurrent to operational flow to gently expand the filter cloth allowing for the cake to be discharged from the filter element surface, is higher than the operating pressure in the Continuous Candle Filter's upright tank [ 50 ], preferably between 15 to 20 PSI greater than the filter housing operating pressure, which operates between 30 and 60 PSIG. The pressure difference between the filtrate transferred to the system from the solvent backflush pump [ 116 ], and the upright tank [ 50 ], is the pressure necessary for the purification of the filter surfaces. It is to be understood that a typical backflush with SVOC-depleted filtrate solvent, in step 954 , requires that the backflush filtrate regen valve [ 120 b ] need be left open for a duration of time less than or equal to 10 seconds.
[0121] After the SVOC-depleted filtrate solvent has been injected through the filter bundle, and once the backflush regen valve has been returned to a closed position, step 956 may commence. Step 956 (filter cake sedimentation) entails allowing a settling time sequence for a duration of time less than or equal to 30 seconds to allow the agglomerated dislodged filter cake solids to sink through both, the solvent phase, and the water phase, thus permitting sufficient time to allow the filtration induced forcibly agglomerated filter cake solids to settle to the bottom lower conical drain section.
[0122] Step 958 (filter cake discharge start) involves opening the respective regenerated filter bundle's filter cake drain valve [ 58 b ] to allow transference of an agglomerated paste-like carbon particulate filter cake material from the system. The process control signal generation mechanism required to end step 958 involves monitoring the signal output from a presence/absence detection flange mounted instrument [ 124 b ], also termed an impedance-sensing device, or the like, which may be installed just upstream prior to the filter cake drain valves to serve the purpose of further automating the system by indicating when the thick paste-like filter cake material has left the system.
[0123] Alternately the sensors may be furnished by the commercial vendor to detect the presence or absence of water within the pipeline thus acting as a control mechanism for closing the drain valve. If the process control signal indicates that the filter cake is being drained from the system, step 958 continues. If, on the other hand, the process control signal indicates that the filter cake has left the system, step 958 will end, and step 960 may begin. Step 960 (filter cake discharge end) entails closing the respective filter cake drain valve [ 58 b ] since solids have been discharged from the system. After step 960 has transpired, step 962 (filtration restart preparation) may commence which entails opening the respective filter bundle's filtrate register valve [ 92 b ] to again commence filtration on the regenerated filter bundle, thus allowing step 950 to commence again, then allowing the filtration and regeneration cycle to repeat itself.
Filter Cake Liquid Removal System
[0124] After the filter cake material is removed from the candle filter vessel, it may be transferred to any sort of commercially available Filter Cake Liquid Removal System [ 8225 ], preferably a belt filter press, or any similar device which applies mechanical pressure to an agglomerated sludge paste-like filter cake to remove residual liquid therefrom. Liquid removed from the filter cake [ 124 ] may be transferred to the plant waste water header, whereas the liquid depleted solids [ 126 ] may be transferred to another location for Liquid Depleted Solids Collection [ 8250 ].
Step D, Option 1, Operation
[0125] FIG. 8 underlines the principles dictating the philosophy of operation of Option 1 of Solids Removal & SVOC Removal Control Volume [D- 1 ] as depicted in FIG. 4 , which are as follows:
[0126] Step D1a:
contacting the unconditioned syngas with a solvent and water to reduce the temperature of the syngas to below the SVOC condensation temperature to thereby form an intermediate SVOC-depleted syngas containing steam, and a first mixture comprising SVOC, solids, solvent and water;
[0128] Step D1b:
removing steam from the intermediate SVOC-depleted syngas containing steam to form: (i) a first depleted syngas stream which has a reduced amount of SVOC relative to the unconditioned gas stream, and (ii) a second mixture comprising SVOC, solids, solvent and water;
[0130] Step D1c:
separating the water within the second mixture based upon immiscibility so that the SVOC, solids and solvent collect together to form a third mixture above the water; separating the solids from the SVOC and solvent in a vessel having at least one liquid phase candle filter such that the solids agglomerate on a surface of the candle filter and form a filter cake having density greater than that of water within the vessel;
[0132] Step D1d:
Backflushing the candle filter to loosen the filter cake so that the filter cake sinks into the water within the vessel; and
[0134] Step D1e:
Removing the filter cake from a bottom of the vessel.
Step D, Option 2
[0136] In an alternate, non-limiting embodiment, the immiscible liquid separation and continuous filtration functionalities of the Continuous Candle Filter Decanter [ 8175 ] may be decoupled.
[0137] Option 2 of Solids Removal & SVOC Removal Control Volume [D- 1 ], as depicted in FIG. 9 and FIG. 10 , utilizes a Decanter [ 8275 ] and Continuous Candle Filter [ 8300 ], which serve a similar function as the Continuous Candle Filter Decanter [ 8175 ]. Separation of immiscible liquids followed by separation of SVOC from the solvent filtrate is the guiding principle to be achieved by installation of the configuration disclosed in Option 2.
[0138] The purpose of the Continuous Candle Filter Decanter [ 8175 ], of Step D Option 1, is to combine the functionality of density separation of liquids together with filtration separation of solids from liquids. It further automates an otherwise batch-wise filter operation so that a continuous cyclic-batch system is realized. As illustrated in FIG. 9 , the Decanter [ 8275 ] and Continuous Candle Filter [ 8300 ] are separate from one another.
[0139] FIG. 9 depicts the Decanter [ 8275 ] and Continuous Candle Filter [ 8300 ] in communication through a solids & SVOC laden solvent filtrate transfer line [ 128 ]. It further depicts the Continuous Candle Filter [ 8300 ] in communication with the SVOC Separation System Control Volume [SVOC- 1 ] through a SVOC laden solvent filtrate transfer line [ 130 ].
[0140] Decanters are well known liquid density separation unit operations commonplace to commercial industrial systems. Furthermore, similarly, candle filters, or the like, are commercially available and their installation, integration, and operation are well known to a person possessing an ordinary skill in the art to which it pertains.
[0141] FIG. 10 outlines the principles dictating the philosophy of operation of Option 2 of Solids Removal & SVOC Removal Control Volume [D- 1 ] as depicted in FIG. 9 , which are as follows:
[0142] Step D1a:
contacting the unconditioned syngas with a solvent and water to reduce the temperature of the syngas to below the SVOC condensation temperature to thereby form an intermediate SVOC-depleted syngas containing steam, and a first mixture comprising SVOC, solids, solvent and water;
[0144] Step D1b:
removing steam from the intermediate SVOC-depleted syngas containing steam to form: (i) a first depleted syngas stream which has a reduced amount of SVOC relative to the unconditioned gas stream, and (ii) a second mixture comprising SVOC, solids, solvent and water;
[0146] Step D1ca:
Separating the water within the second mixture based upon immiscibility so that the SVOC, solids and solvent collect together to form a third mixture above the water;
[0148] Step D1cb:
separating the solids from the SVOC and solvent in a vessel having at least one liquid phase candle filter such that the solids agglomerate on a surface of the candle filter and form a filter cake having density greater than that of water within the vessel;
[0150] Step D1d:
Backflushing the candle filter to loosen the filter cake so that the filter cake sinks into the water within the vessel; and
[0152] Step D1e:
Removing the filter cake from a bottom of the vessel.
SVOC Separation System
[0154] FIG. 11 and FIG. 12 illustrate options for separating SVOC from the filtrate scrubbing solvent.
SVOC Flash Separation System
[0155] The preferred application to remove SVOC from the syngas as depicted in Solids Removal & SVOC Removal Control Volume [D- 1 ], encompasses the utilization of a scrubbing solvent that sorbs SVOC from the syngas. SVOC removal from the scrubbing solvent must take place in order to realize continuous recycle of the scrubbing solvent as well as to avoid the buildup of SVOC within the system leading to operational impairment of the scrubbing operations.
[0156] In order to continuously recycle absorption scrubbing liquid, a SVOC Flash Separation System, as depicted in FIG. 11 , may be employed to flash SVOC from the scrubbing solvent. Preferably this system is employed together with the use of a vacuum system, condenser system, and liquid SVOC collection equipment permitting the recovery of a SVOC product.
[0157] FIG. 11 depicts the preferred non-limiting embodiment for the SVOC Separation System Control Volume [SVOC- 1 ]. SVOC laden filtrate scrubbing solvent is transferred from solvent and char filtration operations through a filtrate solvent transfer line [ 94 ] and routed to the inlet of a SVOC Flash Tank Heat Exchanger [ 8325 ], which is preferably of a shell and tube type heat exchanger. Steam, or another heat source, may communicate with the shell-side of the heat exchanger through a steam inlet line [ 132 ] and a steam discharge line [ 134 ] to transfer heat to the SVOC laden filtrate solvent traveling through the exchanger's tube-side prior to being transferred to the SVOC Flash Tank [ 8350 ]. SVOC laden filtrate scrubbing solvent is discharged from the exchanger's tube-side and routed through a SVOC laden filtrate solvent Flash Tank transfer line [ 136 ] where it then flows through a pressure letdown device [ 138 ], comprised of either a valve, or restriction orifice, that is positioned just upstream of the inlet to the SVOC Flash Tank. Upon release to the lower pressure environment of the SVOC Flash Tank, the SVOC liquid fraction is vaporized, or flashed, from the SVOC laden filtrate solvent and enters the SVOC flash transfer conduit [ 140 ] for condensation and collection of the SVOC product. A SVOC-depleted filtrate solvent is expelled from the lower section of the SVOC Flash Tank where it enters a SVOC-depleted solvent transfer line [ 142 ]. A SVOC-depleted solvent transfer pump [ 144 ], routes the solvent to a Solvent Cooler [ 8375 ] through a solvent transfer line [ 146 ], or it may transfer the solvent back to the SVOC Flash Tank Heat Exchanger [ 8325 ] through a solvent recycle line [ 148 ].
[0158] A cooling water supply [ 150 ] and a cooling water return [ 152 ] communicate with the shell-side of the Solvent Cooler [ 8375 ] and provide the thermal capacity to remove heat from the solvent traveling through the tube-side of the exchanger.
[0159] The SVOC Flash Tank is preferably a vertical cylindrical tank, however it may be a horizontal flash tank with provided distribution pipe, and may be equipped with an impingement baffle [ 154 ] to provide a sudden flow direction change of the flashing SVOC laden filtrate solvent. A plurality of spray nozzles [ 156 ] are positioned in the upper section of the SVOC Flash Tank and are utilized for intermittent washing with a clean in place (CIP) agent transferred to the system through a CIP agent transfer line [ 158 ] and a CIP agent isolation valve [ 160 ]. Cleaning of the vessel preferably is performed only when the solvent is isolated from the SVOC Flash System. The spray nozzles [ 156 ] may also be provided with a source of cooled SVOC-depleted solvent through a cooled SVOC-depleted solvent transfer line [ 162 ] routed from the discharge of the Solvent Cooler [ 8375 ].
[0160] The SVOC Flash Tank Heat Exchanger [ 8325 ] increases the temperature of the SVOC laden solvent stream to above the flash point of SVOC and lesser than, and not equal, to the flash point temperature of the scrubbing solvent. This is to permit vaporization of only the SVOC fraction within the solvent and SVOC liquid mixture upon release to a lower pressure across the pressure letdown device [ 138 ].
[0161] A SVOC Condenser [ 8400 ] accepts SVOC laden vapors from the SVOC vapor transfer conduit [ 140 ] and condenses the SVOC into a liquid state prior to discharging the liquid SVOC from the system through a SVOC Separation System Control Volume SVOC Discharge [SVOC-OUT].
[0162] A SVOC vacuum system transfer line [ 164 ] connects the SVOC Vacuum System [ 8425 ], with the SVOC Condenser [ 8400 ]. The Vacuum system is preferably a liquid ring vacuum pump that uses a liquid SVOC seal fluid [ 166 ] within its pump casing (not shown).
[0163] A cooling water supply [ 170 ] and a cooling water return [ 172 ] communicate with the shell-side of the SVOC Condenser [ 8400 ] and provide the thermal capacity to condense SVOC traveling through the tube-side of the exchanger into a liquid phase.
SVOC Membrane Separation System
[0164] In an alternate non-limiting embodiment, selective sorptive permeation of SVOC from the scrubbing liquid may be employed, as depicted in FIG. 12 which portrays the SVOC Sorptive Separation System. Liquid phase sorption applications, not only including pervaporation membrane processes, may be employed to separate the SVOC from the SVOC laden scrubbing solvent liquid mixture due to selective diffusion of the SVOC molecules based on molecular diameter and polarity.
[0165] SVOC laden filtrate scrubbing solvent may be transferred from the filtrate solvent transfer line [ 94 ] to the inlet of a SVOC Sorptive Separator [ 8475 ]. It is preferred to utilize a SVOC Sorptive Separator [ 8475 ] in a capacity to realize liquid phase pervaporative sorption separation of SVOC from a solvent laden filtrate stream. However a packed bed of adsorbent, either polymeric styrene based adsorbents, or 10 angstom aluminosilicate molecular sieve adsorbents, or a suitable sorption medium possessing an preferential sorption of SVOC from a scrubbing solvent may also be utilized to accomplish a similar result.
[0166] The SVOC Sorptive Separator [ 8475 ] is preferentially comprised of a commercially available permeation unit, preferably a shell and tube device utilizing a tubular membrane selective to hydrophobic non-polar solvents preferably in the form of a PEEK based membrane cast inside a hollow fiber tube.
[0167] The SVOC Sorptive Separator [ 8475 ] may also contain a cluster of membrane elements, and more than one permeation unit may be used to create multiple pervaporation modules, or even multiple stages of pervaporation modules may be utilized. Although a plate and frame type unit may be utilized in conjunction with membrane sheets, the shell and tube type system is preferred due to its ease in manufacture and lower capital cost.
[0168] The SVOC Sorptive Separator [ 8475 ] contains a porous membrane [ 174 ], preferably with a porous chemical resistant coating [ 176 ], having a SVOC laden solvent membrane process surface [ 178 a ], that is exposed to the SVOC laden filtrate scrubbing solvent, and an opposing SVOC permeate membrane process surface [ 178 b ], where the SVOC permeate is volatilized therefrom by a driving force created by preferably a combination of a vacuum driven and a temperature driven gradient created by a downstream vacuum system and condenser as previously described.
[0169] A Guard Filter [ 8450 ] accepts SVOC laden filtrate solvent from the filtrate solvent transfer line [ 94 ] prior to routing it to the SVOC Sorptive Separator [ 8475 ] through a second filtrate solvent transfer line [ 180 ]. The Guard Filter [ 8450 ] is in place to mediate any membrane fouling which may arise due to fine particulate matter blocking membrane flow channels, contributing to clogging of effective membrane void spaces and ultimately causing a gradual decline in the membrane SVOC permeation rate. The Guard Filter [ 8450 ] is preferably an easy access metal filter-bag housing preferably containing a heavy-duty polyester felt filter bag of 0.5 micron effective pore size.
Sequence Step E, Chlorine Removal [E]
[0170] FIG. 13 illustrates Sequence Step E, Chlorine Removal [E], wherein Chlorine Removal Control Volume [E- 1 ] accepts a chlorine laden Sequence Step E Syngas Inlet [E-IN], and outputs a chlorine depleted Sequence Step E Syngas Discharge [E-OUT].
[0171] The Chlorine Scrubber [ 8500 ], configured similar to the Char Scrubber [ 8125 ], is also a vertically oriented cylindrical, or rectangular, pressure vessel having a lower section, and an upper section, along with a central section that contains a specified quantity of packed absorption media, which is supported upon a suitable support grid system commonplace to industrial chemical equipment systems. The upper section of the scrubber preferably contains a demister that is positioned above a scrubber spray nozzle system [ 236 ] which introduces the scrubbing absorption liquid to the scrubber.
[0172] The purpose of the Hydrogen Chloride Scrubber is to remove trace amounts of hydrogen chloride from the syngas by using water condensed from residual steam contained within the syngas as the main scrubbing absorption liquid. It also serves the function to remove any residual particulate elutriated in the syngas.
[0173] Syngas enters the lower section of the Hydrogen Chloride Scrubber and passes up through the scrubber's central section where the syngas vapor comes into intimate contact with the water scrubbing liquid traveling countercurrently via gravity flow down through the scrubber's packing. Water is condensed out of the vapor phase and enters the lower section of the scrubber. A level control loop, comprising a level transmitter [ 200 ], positioned on the lower section of the scrubber, and a level control valve [ 202 ], may be automatically operated to permit water to be bled from the scrubber water recirculation piping [ 238 ], via a waste water transfer conduit [ 240 ], to maintain a steady liquid level within the lower section of the scrubber. A scrubber water recirculation pump [ 276 ], accepts water from the lower section of the scrubber, through the pump suction piping [ 242 ], and transfers the water through a Hydrogen Chloride Scrubber Heat Exchanger [ 8525 ], prior to injecting the water into the scrubber, via the main recirculation piping [ 238 ], which routes the water through the scrubber's spray nozzle system and into the upper section of the scrubber where the flow of liquid is directed downwards onto the scrubber central packing. The Hydrogen Chloride Scrubber Heat Exchanger [ 8525 ] is preferably of the shell and tube type, wherein a cooling water supply [ 246 ], and a cooling water return [ 248 ], communicate with the shell-side of the heat exchanger to fulfill the heat transfer requirements necessary to indirectly remove heat from the process side steam condensate recirculation liquid. Process water [ 214 ] may be transferred to the scrubber water recirculation piping, or the lower section of the scrubber.
Sequence Step F, Sulfur Removal [F]
[0174] FIG. 14 illustrates Sequence Step F, Sulfur Removal [F], wherein Sulfur Removal Control Volume [F- 1 ] accepts a sulfur laden Sequence Step F Syngas Inlet [F-IN], and outputs a sulfur-depleted Sequence Step F Syngas Discharge [F-OUT].
[0175] The Sulfur Scrubber [ 8550 ] is configured similar to the Chlorine Scrubber [ 8500 ]. The upper section of the scrubber preferably contains a demister that is positioned above a scrubber spray nozzle system [ 336 ] which introduces the scrubbing absorption liquid to the scrubber. Syngas enters the lower section of the Sulfur Scrubber and passes up through the scrubber's central section where the syngas vapor comes into intimate contact with a hydrogen sulfide scavenger scrubbing liquid traveling countercurrently via gravity flow downward through the scrubber's packing. The Sulfur Scrubber preferentially utilizes a hydrogen sulfide scavenger as the main scrubbing fluid which is preferably a dilute, nonregenerable, water-soluble, triazine derived solution, preferably of Nalco EC9021A product, diluted with water to between a 0.01 and 1 wt % triazine solution mixture. Glyoxal from BASF, SE-100 H2S Hydrogen Sulfide Scavenger from Sepcor, DTM Triazine from DThree Technology, or Baker Hughes' Petrolite SULFIX™ H2S scavengers may alternately be used. The use of a regenerable hydrogen sulfide scavenger fluid may also be used.
[0176] The Sulfur Scrubber is equipped with a level transmitter [ 300 ], positioned on the lower section of the scrubber, which cooperates with a level control valve [ 302 ] located on a waste transfer conduit [ 340 ]. The recirculation pump [ 376 ] accepts a dilute triazine solution from the lower section of the scrubber, through its pump suction piping [ 342 ], and pumps the liquid to the upper section of the scrubber through the recirculation piping [ 338 ] and through a plurality of spray nozzles which spray the flow downwards onto the scrubber's centrally located packed section.
[0177] A source of process water [ 314 ], along with a source of a fresh concentrated sulfur scavenger derived solution [ 316 ], are available to be injected into the Sulfur Scrubber system, preferably into the recirculation piping [ 338 ].
[0178] Any type of sulfur removal system may be used to achieve the syngas cooling functionality prescribed in Sequence Step F. Some alternatives may be, including, but not limited to, wet limestone scrubbing systems, spray dry scrubbers, claus processing system, solvent based sulfur removal processes such as the UC Sulfur Recovery Process (UCSRP), low-temperature or refrigerated solvent-based scrubbing systems using amines or physical solvents (i.e., Rectisol, Selexol, Sulfinol), high temperature sorbents, glycol ether, diethylene glycol methyl ether (DGM), regenerable and non-regenerable sorbents, molecular sieve zeolites, calcium based sorbents, FeO, MgO or ZnO-based sorbents or catalysts, Iron Sponge, potassium-hydroxide-impregnated activated-carbon systems, impregnated activated alumina, titanium dioxide catalysts, vanadium pentoxide catalysts, tungsten trioxide catalysts, sulfur bacteria (Thiobacilli), sodium biphospahte solutions, aqueous ferric iron chelate solutions, potassium carbonate solutions, alkali earth metal chlorides, magnesium chloride, barium chloride, crystallization techniques, bio-catalyzed scrubbing processes such as the THIOPAQ Scrubber, or hydrodesulphurization catalysts.
Sequence Step G, Particulate Filtration [G]
[0179] FIG. 15 illustrates Sequence Step G, Particulate Filtration [G], wherein the Particulate Filer [ 8575 ] situated within the Particulate Filtration Control Volume [G- 1 ] accepts a particulate laden Sequence Step G Syngas Inlet [G-IN], and outputs a particulate depleted Sequence Step G Syngas Discharge [G-OUT].
Sequence Step H, Syngas Compression [H]
[0180] FIG. 16 illustrates Sequence Step H, Syngas Compression [H], wherein the Syngas Compressor [ 8600 ] accepts a Sequence Step H Syngas Inlet [H-IN], and outputs a Sequence Step H Syngas Discharge [H-OUT]. A gaseous hydrocarbon source [HC-IN] may be optionally routed to the inlet of the Syngas Compressor [ 8600 ] and may include, natural gas, syngas, refinery offgases, naphtha, methanol, ethanol, petroleum, methane, ethane, propane, butane, hexane, benzene, toluene, xylene, or naphthalene, or the like.
Sequence Step I, VOC Removal [I]
[0181] FIG. 17 depicts Sequence Step I, VOC Removal [I], wherein VOC Removal Control Volume [I- 1 ] accepts a VOC laden Sequence Step I Syngas Inlet [I-IN], and outputs a VOC-depleted Sequence Step I Syngas Discharge [I-OUT].
[0182] VOC removal systems are not conventionally found within syngas cleaning or conditioning processes. Experimental results have consistently and repeatedly shown that without Sequence Step I, VOC Removal [I] in place sulfur removal systems could be inhibited downstream allowing contaminants to pass through the system and poison catalysts that are not sulfur tolerant.
[0183] In one non-limiting embodiment, VOC may be removed from syngas by utilizing a heat exchange adsorption process that combines thermal swing regeneration with vacuum pressure swing adsorption (VPSA), as depicted in FIG. 18 .
[0184] In another non-limited embodiment, VOC may be removed from syngas by utilizing a fluidized particulate bed adsorption system wherein VOC saturated adsorbent is regenerated utilizing a vacuum assisted thermal swing desorption process as depicted in FIG. 19 .
Sequence Step I, Option 1
[0185] FIG. 18 depicts Option 1 of Sequence Step I which discloses a separation system that may be used to remove VOC from syngas. The figure portrays a VPSA system with thermal swing desorption capabilities.
[0186] VPSA is a gas separation process in which the adsorbent is regenerated by rapidly reducing the partial pressure of the adsorbed component, either by lowering the total partial pressure or by using a purge gas.
[0187] In a VPSA system, regeneration is achieved by first stopping feed flow, then depressurizing the adsorbent, usually by passing regeneration gas through the bed counter-current to the feed direction. The regenerating gas is generally free of impurities.
[0188] VPSA systems have certain inherent disadvantages, mostly attributed to the short cycle time that characterizes VPSA. In each cycle of operation, the adsorbent is subjected to a feed period during which adsorption takes place, followed by depressurization, regeneration, and repressurization. During the depressurization, the feed gas in the bed is vented off and lost, which is referred to as a “switch loss.” The short cycle time in the VPSA system gives rise to high switch losses and, because the cycle is short, it is necessary that the repressurization is conduced quickly. This rapid repressurization causes transient variations in the feed and product flows, which can adversely affect the plant operation, particularly in the operation of processes downstream of the adsorption process.
[0189] VPSA is best used for components that are not too strongly adsorbed. On the other hand, thermal swing adsorption (TSA) is preferred for very strongly adsorbed components, since a modest change in temperature produces a large change in gas-solid adsorption equilibrium. In the temperature swing process, to achieve regeneration, is it necessary to supply heat to desorb the material. Following regeneration of the sorbent by heating, the sorbent preferably is cooled prior to the next adsorption step, preferably by transferring a cooling fluid, not only including water, through the thermal transfer chambers of each Aromatic Hydrocarbon Micro-Scale Heat Exchange Adsorber [ 8625 A&B].
[0190] In one embodiment, each Aromatic Hydrocarbon Micro-Scale, also termed Microchannel, Heat Exchange Adsorber [ 8625 A&B] includes one or more adsorption chambers [ 402 ] each of which may be tubular or rectangular in shape and each chamber is separated from the adjacent chamber(s) by a thermal transfer chamber [ 404 ]. Each adsorption chamber is provided with a feed inlet [ 406 a & 406 b ] for introducing VOC laden syngas, a product outlet [ 408 a & 408 b ] for removing VOC-depleted syngas from the adsorption chamber, and a particulate bed [ 410 ] comprising sorbent particles disposed within the chamber. It is desirable for the adsorption chambers to be relatively narrow to ensure rapid heat transfer, and thus is it our realization that a micro-scale heat exchanger, also termed a microchannel heat exchanger, is the preferred unit operation to be utilized in this particular application. In another non-limiting embodiment, each Aromatic Hydrocarbon Adsorber [ 8625 A&B] are comprised of fixed beds without thermal transfer chambers [ 404 ]. It is to be understood that although FIG. 18 depicts parallel first and second adsorbers capable of being operated such that while the first heat exchange adsorber is in an adsorption mode, the second heat exchange adsorber is in a regeneration mode, more than two adsorbers may be used so that one adsorber is off-line.
[0191] The particulate bed preferably contains an adsorption medium that selectively adsorbs VOC into the pores of adsorbent versus any other syngas constituents. In one embodiment, the adsorbent is a styrene based polymeric adsorbent, such as Dowex Optipore V503, or the like. In another embodiment, the adsorbent may be made up of molecular sieves, zeolites, catalyst materials, silica gel, alumina, activated carbon materials, or combinations thereof.
[0192] Each thermal transfer chamber is equipped with thermal transfer chamber inlet valve [ 412 a & 412 b ]. A coolant material, not only including water, or a heating material, not only including steam, may be introduced into the thermal transfer chamber. The coolant material may remove heat from the adjacent adsorption chambers by thermal transfer. The heating material can add heat to the adjacent adsorption chambers also by thermal transfer.
[0193] When the first adsorber unit [ 8625 A] is in an adsorption mode, the second adsorber [ 8625 B] is in regeneration mode where the second adsorber is first depressurized, then purged with the VOC-depleted syngas stream and finally re-pressurized. During this part of the cycle, the first inlet valve [ 414 a ] is open and the second first inlet valve [ 414 b ] is closed directing the syngas feed from line [I-IN] into the first adsorber [ 8625 A]. As the VOC laden syngas passes through the adsorber [ 8625 A], VOC adsorbate is selectively adsorbed into the pores of the adsorbent and the VOC-depleted syngas passes through a first product outlet valve [ 416 a ] and transferred from the VOC separation system through Sequence Step I Syngas Discharge [I-OUT]. During the entire regeneration process, second product outlet valve [ 416 b ] is closed to prevent flow of regenerate into the VOC-depleted syngas stream.
[0194] Under regeneration conditions, the second adsorber [ 8625 B] is first depressurized. During depressurization, both the first purge inlet valve [ 418 a ] and second purge inlet valve [ 418 b ] are closed to prevent purge from entering the second adsorber [ 8625 B] during depressurization. The first depressurization valve [ 420 a ] is closed to prevent flow of the VOC laden syngas stream [I-IN] into the regenerate product line [ 430 ]. The first thermal transfer chamber inlet valve [ 412 a ] is closed to prevent heat addition to the first adsorber [ 8625 A] undergoing adsorption, and the second thermal transfer chamber inlet valve [ 412 b ] on the second adsorber [ 8625 B] is open to allow transfer of heat to the regenerating VOC saturated adsorbent. The second depressurization outlet valve [ 420 b ] is open allowing flow from the second adsorber [ 8625 B] through the regenerate product line [ 430 ]. The regenerate product will contain a mixture of syngas and VOC. The regenerate product line is under a vacuum condition as a result of the VOC Vacuum System [ 8675 ]. The regenerate product flows freely from the pressurized second adsorber [ 8625 B] along the regenerate product line [ 430 ].
[0195] Once the second adsorber is fully depressurized, the second purge inlet valve [ 418 b ] is opened allowing flow of VOC-depleted syngas to purge the VOC that is selectively adsorbed in the pores of the adsorbent and withdraw such purge stream along regenerate product line [ 430 ] under vacuum conditions. Simultaneous to the time when the purge inlet valve is opened, the second adsorber's thermal transfer chamber inlet valve [ 412 b ] is opened to indirectly transfer thermal energy to the depressurized regenerating adsorber [ 8625 B] to aide the removal of VOC adsorbate from the pores of the adsorbent which is under vacuum conditions. Once the purge and heat addition steps are complete for the second adsorber [ 8625 B], depressurization outlet valve [ 420 b ] is closed while purge inlet valve [ 418 b ] remains open so that VOC-depleted syngas from the first adsorber [ 8625 A] can pressurize the second adsorber [ 8625 B] to the same pressure as the first adsorber [ 8625 B]. Coolant may be exchanged for the heat source transferred to the second adsorber [ 8625 B] through the second thermal transfer chamber inlet valve [ 412 b ] and into the thermal transfer chamber [ 404 ] of the second adsorber [ 8625 B] to cool the adsorbent media within the adsorption chamber to prepare it for the next adsorption sequence.
[0196] Once the second adsorber [ 8625 B] is fully pressurized, it is ready for its function to switch from regeneration to adsorption. At this point, the adsorbent in the first adsorber [ 8625 A] has selectively adsorbed a considerable amount of VOC. The first adsorber [ 8625 A] is ready for regeneration. The two beds switch function. This occurs by the following valve changes. The first product outlet valve [ 416 a ] is closed, and the first inlet valve [ 414 a ] is closed. The first purge inlet valve [ 418 a ] remains closed, and the first depressurization outlet valve [ 420 a ] is opened to begin depressurization of the first adsorber [ 8625 A]. The second thermal transfer chamber inlet valve [ 412 b ] is closed and the first thermal transfer chamber inlet valve [ 412 a ] is opened to allow thermal energy to be transferred to the first adsorber [ 8625 A] thermal transfer chamber [ 404 ].
[0197] Adsorption begins for the second adsorber [ 8625 B] with the following valve arrangement. The second depressurization outlet valve [ 420 b ] remains closed. The second purge inlet valve [ 418 b ] is closed. The second product outlet valve [ 416 b ] is opened, and the first inlet valve [ 414 b ] is opened to facilitate flow from the VOC laden syngas stream [I-IN] into the second adsorber and flow of VOC-depleted syngas from the second adsorber [ 8625 B] through second product outlet valve [ 416 b ] into the VOC-depleted syngas stream [I-OUT]. The regeneration process as described above for the second adsorber [ 8625 B] is repeated for the first adsorber [ 8625 A].
[0198] Preferably, the regeneration occurs at a pressure below atmospheric pressure under a vacuum created by the VOC Vacuum System [ 8675 ]. The regenerate leaves the second adsorber [ 8625 B] as a vapor stream. It is cooled in a VOC Condenser [ 8650 ] supplied with a cooling water supply [ 470 ] and a cooling water return [ 472 ]. Condensed VOC regenerate product is withdrawn along stream through VOC Separation System Control Volume VOC Discharge [VOC-OUT].
[0199] A VOC vacuum system transfer line [ 464 ] connects the VOC Vacuum System [ 8675 ], with the VOC Condenser [ 8650 ]. The Vacuum system is preferably a liquid ring vacuum pump that uses a liquid VOC seal fluid [ 466 ] within its pump casing (not shown).
[0200] This system is preferably operated during adsorption at a pressure of 25 psia of greater and preferably 300 psia of greater. The VPSA system during regeneration of the bed, in one embodiment, is operated at less than atmospheric pressure. In one embodiment, the VPSA system is operated at a pressure of 7.5 psia or less and preferably 5 psia or less to regenerate the bed. In one embodiment, the VPSA system uses a two bed system. Optionally a three bed system is used. In another embodiment, four or more beds are used.
Sequence Step I, Option 2
[0201] In another non-limiting embodiment, VOC may be removed from syngas by utilization of a continuous pressurized fluidized particulate bed adsorption system whereby VOC laden syngas is used to fluidize a particulate bed containing an adsorption medium that selectively adsorbs VOC.
[0202] FIG. 19 depicts, Sequence Step I, VOC Removal [I], Option 2 as the embodiment situated within VOC Removal Control Volume [I- 1 ]. An Aromatic Hydrocarbon Fluidized Sorption Bed [ 8700 ] accepts VOC laden syngas from stream [1-IN] and outputs a VOC-depleted syngas through stream [1-OUT].
[0203] VOC laden syngas is introduced into the Aromatic Hydrocarbon Fluidized Sorption Bed [ 9700 ] through a distribution plate [ 474 ], which may be positioned below an optional support grid system [ 476 ] with a suitable screen to prevent reverse-flow of absorbent into the inlet conduit [I-IN].
[0204] Syngas fluidizes the adsorbent bed material [ 478 ] which adsorbs VOC from the vapor bubbles [ 480 ] passing up through the bed. An optional internal cyclone [ 482 ] may be positioned within the freeboard section [ 484 ] of the fluidized bed to separate the adsorbent from the VOC-depleted syngas, and return the adsorbent to the bed via a cyclone dipleg [ 486 ].
[0205] Desorption of VOC from the VOC saturated adsorbent takes place within the indirectly heated Regen Heat Exchange Fluidized Bed [ 8725 ]. In order for the Aromatic Hydrocarbon Fluidized Sorption Bed [ 8700 ] to realize a continuous separation of VOC from syngas, adsorbent bed material [ 478 ] must be moved from the bed, regenerated, and then transported back to the bed. A series of alternating solids handling valves [490a & 490 b ], configured in a lock hopper arrangement, may be used to batch-transfer volumes of adsorbent bed material [ 478 ] through VOC adsorbent transfer conduit [ 488 ] to the Regen Heat Exchange Fluidized Bed [ 8725 ]. Lock hopper valve arrangements are well known in the art to which it pertains and are commonly used to transfer solids from one isolated pressurized environment to another.
[0206] Sequence Step I, VOC Removal [I], Option 2 is preferentially installed prior to Syngas Compression Sequence Step [H]. Therefore, the preferred operating pressure range for the Aromatic Hydrocarbon Fluidized Sorption Bed [ 8700 ] of Sequence Step I, Option 2 ranges from 30 to 75 psia. The regenerate product line [ 430 ] connected to the Regen Heat Exchange Fluidized Bed [ 8725 ] is held under vacuum conditions as described in FIG. 18 . The Regen Heat Exchange Fluidized Bed [ 8725 ] is operated under vacuum conditions at a pressure 14.5 psia or less and preferably 8.5 psia or less.
[0207] The Regen Heat Exchange Fluidized Bed [ 8725 ] is continuously fluidized with a VOC-depleted vapor source [ 492 ], preferably with FT tailgas, however, steam, compressed syngas, or any other available vapor, such as nitrogen or air may be used instead.
[0208] The VOC-depleted vapor source [ 492 ] is introduced into the Regen Heat Exchange Fluidized Bed [ 8725 ] through a distribution plate [ 494 ], which may be positioned below an optional support grid system [ 496 ] with a suitable screen. A heat source [ 498 ], preferably steam, is made available to at least one heat transfer chamber [ 500 ] that shares at least one heat transfer surface [ 502 ] with that of the fluidized adsorbent bed material [ 478 ] contained within the Regen Heat Exchange Fluidized Bed [ 8725 ]. This allows thermal energy to be indirectly transferred into the bed to allow a temperature aided desorption of VOC from the pores of the adsorbent material that is fluidized with the VOC-depleted vapor source [ 492 ]. VOC will be released from the adsorbent material within the bed and will enter the vapor bubbles [ 504 ] as they pass up through the bed.
[0209] An optional internal cyclone [ 508 ] may be positioned within the freeboard section [ 512 ] of the fluidized bed to separate the adsorbent from the VOC laden vapor, and return the adsorbent to the bed via a cyclone dipleg [ 514 ]. A series of alternating solids handling valves [ 516 a & 516 b ], configured in a lock hopper arrangement, may be used to batch-transfer volumes of regenerated adsorbent bed material [ 478 ] through transfer conduit [ 518 ] to the Sorbent Transfer Tank [ 8750 ].
[0210] The Sorbent Transfer Tank [ 8750 ] is a cylindrical pressure vessel equipped with a dip tube [ 520 ], pressurized vapor source [ 522 ], and solids handling valves [ 524 a & 524 b ], which are used together in combination to transport regenerated adsorbent bed material [ 478 ] back to the Aromatic Hydrocarbon Fluidized Sorption Bed [ 8700 ] through regen adsorbent transport line [ 526 ]. Regenerated adsorbent bed material [ 478 ] is first transferred from the Regen Heat Exchange Fluidized Bed [ 8725 ] to the Sorbent Transfer Tank [ 8750 ] through solids handling valves [ 516 a & 516 b ]. The Sorbent Transfer Tank [ 8750 ] is the isolated and pressurized with the vapor source [ 522 ] by opening solids handling valve [ 524 a ] while valve 524 b is closed. When the pressure in the Sorbent Transfer Tank [ 8750 ] exceeds that of the Aromatic Hydrocarbon Fluidized Sorption Bed [ 8700 ], the valve positions of solids handling valves [ 524 a & 524 b ] are switched allowing regenerated adsorbent bed material [ 478 ] to be conveyed via a pressure surge from the Sorbent Transfer Tank [ 8750 ] up through the dip tube [ 520 ], and through the regen adsorbent transport line [ 526 ], where it may then enter the Aromatic Hydrocarbon Fluidized Sorption Bed [ 8700 ]. The regenerated adsorbent bed material [ 478 ] may either free fall through the freeboard section [ 484 ], or if perforated trays [ 528 ] are installed in the freeboard section [ 484 ], the regenerated adsorbent bed material [ 478 ] may gradually trickle down through the vessel and thus improve gas to solid contact.
[0211] In another non-limiting embodiment, the Regen Heat Exchange Fluidized Bed [ 8725 ] may be operated under positive pressure conditions wherein VOC may be condensed and recovered as disclosed in FIG. 18 . In this particular embodiment, a VOC laden gaseous hydrocarbon vapor [ 430 ] may then exit the Regen Heat Exchange Fluidized Bed [ 8725 ], where it then may be made available as a fuel source to the Hydrocarbon Reformer [ 8000 ] of Sequence Step B, Hydrocarbon Reforming [B].
Sequence Step J, Metal Removal [J]
[0212] FIG. 20 depicts Sequence Step J, Metal Removal [J], wherein Metal Removal Control Volume [J- 1 ] accepts a metal laden Sequence Step J Syngas Inlet [J-IN], and outputs a metal depleted Sequence Step J Syngas Discharge [J-OUT].
[0213] Metal Guard Bed [ 8775 ] is preferably comprised of vertical cylindrical pressure vessel containing cellulose acetate packing media possessing an affinity to sorb heavy metals, not only including, mercury, arsenic, lead, and cadmium. The cellulose acetate may be in the form of beads, spheres, flake, or pellets. Alternatively, sorbents such as Mersorb, from NUCON International, Inc., or AxTrap 277 from Axens-IFP Group Technologies, or the like, may be used.
Sequence Step K, Ammonia Removal [K]
[0214] FIG. 21 depicts Sequence Step K, Ammonia Removal [K], wherein Ammonia Removal Control Volume [K- 1 ] accepts an ammonia laden Sequence Step K Syngas Inlet [K-IN], and outputs an ammonia-depleted Sequence Step K Syngas Discharge [K-OUT].
[0215] The Ammonia Scrubber [ 8800 ], configured similar to the Chlorine Scrubber [ 8500 ], is also a vertically oriented cylindrical, or rectangular, pressure vessel having a lower section, and an upper section, along with a central section that contains a specified quantity of packed absorption media, which is supported upon a suitable support grid system commonplace to industrial chemical equipment systems. The upper section of the scrubber preferably contains a demister that is positioned above a scrubber spray nozzle system [ 736 ] which introduces the scrubbing absorption liquid to the scrubber.
[0216] The purpose of the Ammonia Scubber is to remove trace amounts of nitrogenated compounds including ammonia and hydrogen cyanide from the syngas by using water as the main scrubbing absorption liquid.
[0217] Syngas enters the lower section of the Ammonia Scubbber and passes up through the scrubber's central section where the syngas vapor comes into intimate contact with the water scrubbing liquid traveling countercurrently via gravity flow down through the scrubber's packing. A level control loop, comprising a level transmitter [ 700 ], positioned on the lower section of the scrubber, and a level control valve [ 702 ], may be automatically operated to permit water to be bled from the scrubber water recirculation piping [ 738 ], via a waste water transfer conduit [ 740 ], to maintain a steady liquid level within the lower section of the scrubber. A scrubber water recirculation pump [ 776 ], accepts water from the lower section of the scrubber, through the pump suction piping [ 742 ], and transfers the water through the scrubber's spray nozzle system [ 736 ] and into the upper section of the scrubber where the flow of liquid is directed downwards onto the scrubber central packing. Process water [ 714 ] may be transferred to the scrubber water recirculation piping, or the lower section of the scrubber.
Sequence Step L, Ammonia Polishing [L]
[0218] FIG. 22 depicts Sequence Step L, Ammonia Polishing [L], wherein Ammonia Polishing Control Volume [L- 1 ] accepts a Sequence Step L Syngas Inlet [L-IN], and outputs a Sequence Step L Syngas Discharge [L-OUT].
[0219] The Ammonia Guard Bed [ 8825 ] is comprised of preferably a vertical cylindrical pressure vessel containing molecular sieve type 4A which possess an affinity to sorb trace amounts of nitrogenated compounds including ammonia and hydrogen cyanide. Alternatively, sorbents such 5A, 13×, dealuminated faujasite, dealuminated pentasil, and clinoptilolite, or the like, may be used.
Sequence Step M, Heat Addition [M]
[0220] FIG. 23 depicts Sequence Step M, Heat Addition [M], wherein Heat Addition Control Volume [M- 1 ] accepts a Sequence Step M Syngas Inlet [M-IN], and outputs a Sequence Step M Syngas Discharge [M-OUT].
[0221] The Heat Exchanger [ 8850 ] is preferably of a shell- and tube type, where syngas is routed to the tube-side. Steam located on the shell-side of the exchanger elevates the temperature of the syngas from between 75 to 125 degrees F. to between 350 and 450 degrees Fahrenheit.
[0222] The Heat Exchanger [ 8850 ] is equipped with a heat source [ 780 ] and a heat discharge [ 782 ] that communicate with the shell-side to indirectly transfer heat to the syngas. Alternately, the heater may be electrically driven, or flue gas or another alternate heat source may be utilized in the place of steam to increase the temperature of the syngas.
Sequence Step N, Carbonyl Sulfide Removal [N]
[0223] FIG. 24 depicts Sequence Step N, Carbonyl Sulfide Removal [N], wherein Carbonyl Sulfide Removal Control Volume [N- 1 ] accepts a carbonyl sulfide laden Sequence Step N Syngas Inlet [N-IN], and outputs a sulfur-depleted Sequence Step N Syngas Discharge [N-OUT].
[0224] The Carbonyl Sulfide Hydrolysis Bed [ 8875 ] is comprised of preferably a vertical cylindrical pressure vessel containing a packed bed media, comprised of alumina or titania, either in the form of beads, pellets, granules, spheres, packing, or the like and serves the purpose to hydrolyze carbonyl sulfide into hydrogen sulfide and carbon dioxide prior to the hydrogen sulfide polishing step. Water [ 790 ] in the form of steam may be injected into the hydrolysis bed aide the carbonyl sulfide to react with water to hydrolyze into hydrogen sulfide and carbon dioxide over the packed bed media. It is preferred to accomplish the goals of this sequence step with the utilization of a packed bed of an alumina based material which allows for the hydrolysis of carbonyl sulfide into carbon dioxide and hydrogen sulfide, however any type of carbonyl sulfide removal system or method, such as adsorption or absorption type systems, may be employed to accomplish the goal of the sequence step to remove carbonyl sulfide from syngas.
Sequence Step O, Sulfur Polishing [O]
[0225] FIG. 25 depicts Sequence Step O, Sulfur Polishing [ 0 ], wherein Sulfur Polishing Control Volume [O- 1 ] accepts Sequence Step O Syngas Inlet [O-IN], and outputs Sequence Step O Syngas Discharge [O-OUT].
[0226] The Sulfur Guard Bed [ 8900 ] is comprised of preferably a vertical cylindrical pressure vessel containing a sorbent media, comprised of zinc oxide in the form of beads, pellets, granules, spheres, packing, or the like and serves the purpose to adsorb trace amounts of hydrogen sulfide and elemental sulfur.
Sequence Step P, Carbon Dioxide Removal [P]
[0227] FIG. 26 depicts Sequence Step P, Carbon Dioxide Removal [P], wherein Carbon Dioxide Removal Control Volume [P- 1 ] accepts a carbon dioxide laden Sequence Step P Syngas Inlet [P-IN], and outputs a carbon dioxide depleted Sequence Step P Syngas Discharge [P-OUT]. The Heat Exchange CO2 Separator serves the purpose to remove the carbon dioxide from the pressurized syngas and recycle it for utilization somewhere else. It is preferred to recycle the separated carbon dioxide as an oxidant within the Hydrocarbon Reformer [ 8000 ], or for use in the upstream syngas generation process as a fluidization medium, or as vapor purges on instrumentation and sampling ports and connections.
[0228] The equipment functionality as described above in Sequence Step I, Option 1, of FIG. 18 is identical to that of the preferred embodiment situated within Dioxide Removal Control Volume [Q- 1 ] of Sequence Step P, Carbon Dioxide Removal [P]. However, one main difference exists in that the Heat Exchange CO2 Separator [ 8925 A&B] is preferentially comprised of a shell and tube heat exchanger, preferably equipped with ½″ diameter tubes. It is preferred to dispose an activated carbon fiber material, preferably in the form of spiral wound activated carbon fiber fabric, or braided activated carbon fiber cloth strands, within the tube side particulate bed [ 810 ] of the vessel while the shell-side thermal transfer chamber [ 804 ] runs empty except when undergoing a regeneration cycle.
[0229] The regeneration process as described above in Sequence Step I, Option 1, of FIG. 18 is identical to that of the preferred embodiment situated within Dioxide Removal Control Volume [P- 1 ] of Sequence Step P, Carbon Dioxide Removal [P], except for the fact that the Sequence Step P does not utilize a vacuum system. Instead, the regenerate product line [ 830 ] is in communication with a Carbon Dioxide Accumulator [ 8950 ]. The purpose of the Carbon Dioxide Accumulator [ 8950 ] is to provide sufficient volume and residence time for regenerated carbon dioxide laden syngas vapors, transferred from a regeneration cycle, to be stored for utilization somewhere else by transferring the carbon dioxide through a Sequence Step P Carbon Dioxide Discharge [CO2-OUT]. The accumulator operates at a pressure of 100 to 165 psia.
[0230] Alternatively, a membrane or sorption based carbon dioxide recovery unit may be used to accomplish the goals of carbon dioxide removal and recovery defined by Sequence Step P, Carbon Dioxide Removal [P]. In a further embodiment, carbon dioxide may be reduced within this sequence step by use of a carbon dioxide electrolyzer.
Sequence Step Q, R, S: Heat Addition [Q]; Steam Methane Reforming [R]; Heat Removal [S]
[0231] With reference to FIG. 27 , Sequence Step Q, Heat Addition [Q], Sequence Step R, Steam Methane Reforming [R], and Sequence Step S, Heat Removal [S] are combined in a preferred fashion as to realize an energy integrated system capable of reforming hydrocarbons present in the inlet syngas source [P-IN]. This configuration is preferred when utilizing the optional gaseous hydrocarbon source [HC-IN] routed to the inlet of the Syngas Compressor [ 8600 ].
[0232] A Heat Exchanger [ 8975 ] accepts a gaseous hydrocarbon laden syngas Sequence Step Q Syngas Inlet [Q-IN] and elevates its temperature to the operating temperature of the Steam Methane Reformer [ 9000 ]. This is accomplished by utilization of heat transfer integration with the reformed cleaned and conditioned syngas [R-OUT] transferred a the shared heat transfer surface within the Heat Exchanger [ 8975 ]. An oxidant source [ 850 ] is made available to the Steam Methane Reformer [ 9000 ] to ensure complete decomposition of the gaseous hydrocarbons into carbon monoxide and hydrogen. A cooled syngas depleted of undesirable gaseous hydrocarbons [S-OUT] is discharged from the Heat Exchanger [ 8975 ] to be made available to a downstream syngas processing technology.
Syngas Processing Embodiments
[0233] Those of ordinary skill in the art will recognize that fewer that all of the steps B-S of FIG. 1 may be used in a given syngas processing method and system.
[0234] For instance, in a first syngas processing method, only steps C, D, G, H, K, O and T may be practiced, and the corresponding system will include the equipment required to implement these steps.
[0235] In a second syngas processing method, only steps B, C, D, F, G, H, I, K, M, N, O and T may be practiced, and the corresponding system will include the equipment required to implement these steps.
[0236] FIGS. 30A-30F present a number of syngas processing embodiments that one might wish to implement. Each row of the table in FIGS. 30A-30F presents the steps to be practiced in a single syngas processing embodiment. It is understood that the corresponding elements necessary to realize each such method would be needed in a system for that embodiment. method.
EQUIPMENT LIST
[0237] The following list of equipment presents items that should be understandable to those of ordinary skill in the art familiar of syngas processing.
8000 Hydrocarbon Reformer 8025 Heat Recovery Steam Generator (HRSG) Superheater 8050 Heat Recovery Steam Generator (HRSG) 8075 Steam Drum 8100 Venturi Scrubber 8125 Char Scrubber 8150 Char Scrubber Heat Exchanger 8175 Continuous Candle Filter Decanter 8200 Filtrate Backflush Buffer Tank 8225 Filter Cake Liquid Removal System 8250 Liquid Depleted Solids Collection 8275 Decanter 8300 Continuous Candle Filter 8325 SVOC Flash Tank Heat Exchanger 8350 SVOC Flash Tank 8375 Solvent Cooler 8400 SVOC Condenser 8425 SVOC Vacuum System 8450 Guard Filter 8475 SVOC Sorptive Separator 8500 Chlorine Scrubber 8525 Chlorine Scrubber Heat Exchanger 8550 Sulfur Scrubber 8575 Particulate Filter 8600 Syngas Compressor 8625 Aromatic Hydrocarbon Micro-Scale Heat Exchange Adsorber 8650 VOC Condenser 8675 VOC Vacuum System 8700 Aromatic Hydrocarbon Fluidized Sorption Bed 8725 Regen Heat Exchange Fluidized Bed 8750 Sorbent Transfer Tank 8775 Metals Guard Bed 8800 Ammonia Scrubber 8825 Ammonia Guard Bed 8850 Heat Exchanger 8875 Carbonyl Sulfide Hydrolysis Bed 8900 Sulfur Guard Bed 8925 Heat Exchange CO2 Separator 8950 Carbon Dioxide Accumulator 8975 Heat Exchanger 9000 Steam Methane Reformer
LIST OF REFERENCE NUMERALS
[0000]
Sequence Step B Syngas Inlet [B-IN]
Sequence Step B Syngas Discharge [B-OUT]
Sequence Step C Syngas Inlet [C-IN]
Sequence Step C Syngas Discharge [C-OUT]
Sequence Step D Syngas Inlet [D-IN]
Sequence Step D Syngas Discharge [D-OUT]
SVOC Separation System Control Volume SVOC Discharge [SVOC-OUT]
Sequence Step E Syngas Inlet [E-IN]
Sequence Step E Syngas Discharge [E-OUT]
Sequence Step F Syngas Inlet [F-IN]
Sequence Step F Syngas Discharge [F-OUT]
Sequence Step G Syngas Inlet [G-IN]
Sequence Step G Syngas Discharge [G-OUT]
optional gaseous hydrocarbon source [HC-IN]
Sequence Step H Syngas Inlet [H-IN]
Sequence Step H Syngas Discharge [H-OUT]
Sequence Step I Syngas Inlet [I-IN]
VOC Separation System Control Volume VOC Discharge [VOC-OUT]
Sequence Step I Syngas Discharge [I-OUT]
Sequence Step J Syngas Inlet [J-IN]
Sequence Step J Syngas Discharge [J-OUT]
Sequence Step K Syngas Inlet [K-IN]
Sequence Step K Syngas Discharge [K-OUT]
Sequence Step L Syngas Inlet [L-IN]
Sequence Step L Syngas Discharge [L-OUT]
Sequence Step M Syngas Inlet [M-IN]
Sequence Step M Syngas Discharge [M-OUT]
Sequence Step N Syngas Inlet [N-IN]
Sequence Step N Syngas Discharge [N-OUT]
Sequence Step O Syngas Inlet [O-IN]
Sequence Step O Syngas Discharge [O-OUT]
Sequence Step P Syngas Inlet [P-IN]
Sequence Step P Syngas Discharge [P-OUT]
Sequence Step P Carbon Dioxide Discharge [CO2-OUT]
Sequence Step Q Syngas Inlet [Q-IN]
Sequence Step Q Syngas Discharge [Q-OUT]
Sequence Step R Syngas Inlet [R-IN]
Sequence Step R Syngas Discharge [R-OUT]
Sequence Step S Syngas Inlet [S-IN]
Sequence Step S Syngas Discharge [S-OUT]
Hydrocarbon Reforming Control Volume [B- 1 ]
Syngas Cooling Control Volume [C- 1 ]
Solids Removal & SVOC Removal Control Volume [D- 1 ]
Chlorine Removal Control Volume [E- 1 ]
Sulfur Removal Control Volume [F- 1 ]
Particulate Filtration Control Volume [G- 1 ]
VOC Removal Control Volume [I- 1 ]
Metal Removal Control Volume [J- 1 ]
Ammonia Removal Control Volume [K- 1 ]
Ammonia Polishing Control Volume [L- 1 ]
Heat Addition Control Volume [M- 1 ]
Carbonyl Sulfide Removal Control Volume [N- 1 ]
Sulfur Polishing Control Volume [O- 1 ]
Carbon Dioxide Removal Control Volume [P- 1 ]
SVOC Separation System Control Volume [SVOC- 1 ]
additives [ 2 ]
oxidant source[ 4 ]
gaseous hydrocarbon source [ 6 ]
superheated steam [ 8 ]
HRSG transfer line [ 10 ]
water [ 12 ]
steam and water mixture [ 14 ]
pressure transmitter [ 16 ]
pressure control valve [ 18 ]
saturated steam transfer line [ 20 ]
level transmitter [ 22 ]
level control valve [ 24 ]
water supply line [ 26 ]
steam drum continuous blowdown line [ 28 ]
Venturi Scrubber recirculation water line [ 30 ]
Venturi Scrubber recirculation solvent line [ 32 ]
Venturi Scrubber to Char Scrubber transfer conduit [ 34 ]
scrubber spray nozzle system [ 36 ]
Char Scrubber recirculation water [ 38 ]
Char Scrubber recirculation solvent [ 40 ]
Char Scrubber underflow downcomer [ 42 ]
common water recirculation line [ 44 ]
cooling water supply [ 46 ]
cooling water return [ 48 ]
upright tank [ 50 ]
central section [ 52 ]
closed dome shaped top [ 54 ]
conical lower sections [ 56 a & 56 b]
drain valve [ 58 a & 58 b]
drain line [ 60 a & 60 b]
vertical underflow weir [ 62 ]
upright vertical housing wall [ 64 ]
annular passageway [ 66 ]
common water header [ 68 ]
water take-off nozzles [ 70 a & 70 b]
water recirculation pump [ 72 ]
inner solvent chamber [ 74 ]
solvent and water interface rag-layer [ 78 ]
filter bundles [ 80 a & 80 b]
candle filter elements [ 82 ]
filter bundle common register [ 84 a & 84 b]
filtrate removal conduit [ 86 a & 86 b]
filtrate process pump [ 88 ]
common filtrate suction header [ 90 ]
filtrate register valve [ 92 a & 92 b]
filtrate solvent transfer line [ 94 ]
alternate backflush transfer line [ 95 ]
common solvent recirculation line [ 96 ]
pressure transmitters [ 98 a & 98 b]
housing pressure transmitter [ 100 ]
flow indicating sight glasses [ 102 a & 102 b]
SVOC-depleted solvent transfer line [ 104 ]
level transmitter [ 106 ]
solvent supply level control valve [ 108 ]
solvent supply line [ 110 ]
solvent backflush pump [ 112 ]
filtrate transfer conduit [ 114 ]
backflush tank recirculation line [ 116 ]
restriction orifice [ 118 ]
backflush filtrate regen valves [ 120 a & 120 b]
filtrate backflush regen conduit [ 122 a & 122 b]
liquid removed from the filter cake [ 124 ]
waste water header [ 126 ]
solids & SVOC laden solvent filtrate transfer line [ 128 ]
SVOC laden solvent filtrate transfer line [ 130 ]
alternate backflush transfer line [ 131 ]
steam inlet line [ 132 ]
steam discharge line [ 134 ]
SVOC laden filtrate solvent Flash Tank transfer line [ 136 ]
pressure letdown device [ 138 ]
SVOC flash transfer conduit [ 140 ]
SVOC-depleted solvent transfer line [ 142 ]
SVOC-depleted solvent transfer pump [ 144 ]
solvent transfer line [ 146 ]
solvent recycle line [ 148 ]
cooling water supply [ 150 ]
cooling water return [ 152 ]
impingement baffle [ 154 ]
spray nozzles [ 156 ]
CIP agent transfer line [ 158 ]
CIP agent isolation valve [ 160 ]
cooled SVOC-depleted solvent transfer line [ 162 ]
SVOC vacuum system transfer line [ 164 ]
liquid SVOC seal fluid [ 166 ]
vacuum system vent line [ 168 ]
cooling water supply [ 170 ]
cooling water return [ 172 ]
porous membrane [ 174 ]
porous chemical resistant coating [ 176 ]
SVOC laden solvent membrane process surface [ 178 a]
SVOC permeate membrane process surface [ 178 b]
filtrate solvent transfer line [ 180 ]
level transmitter [ 200 ]
level control valve [ 202 ]
process water [ 214 ]
scrubber spray nozzle system [ 236 ]
scrubber water recirculation piping [ 238 ]
water transfer conduit [ 240 ]
pump suction piping [ 242 ]
cooling water supply [ 246 ]
cooling water return [ 248 ]
recirculation pump [ 276 ]
level transmitter [ 300 ]
level control valve [ 302 ]
process water [ 314 ]sulfur scavenger derived solution [ 316 ]
scrubber spray nozzle system [ 336 ]
scrubber water recirculation piping [ 338 ]
water transfer conduit [ 340 ]
pump suction piping [ 342 ]
recirculation pump [ 376 ]
adsorption chamber [ 402 ]
thermal transfer chamber [ 404 ]
feed inlet [ 406 a & 406 b]
product outlet [ 408 a & 408 b]
particulate bed [ 410 ]
thermal transfer chamber inlet valve [ 412 a & 412 b]
inlet valve [ 414 a & 414 b]
product outlet valve [ 416 a & 416 b]
purge inlet valve [ 418 a & 418 b]
depressurization valve [ 420 a & 420 b]
modulating purge valve [ 422 ]
regenerate product line [ 430 ]
VOC vacuum system transfer line [ 464 ]
liquid VOC seal fluid [ 466 ]
vacuum system vent line [ 468 ]
cooling water supply [ 470 ]
cooling water return [ 472 ]
distribution plate [ 474 ]
support grid system [ 476 ]
adsorbent bed material [ 478 ]
vapor bubbles [ 480 ]
internal cyclone [ 482 ]
freeboard section [ 484 ]cyclone dipleg [ 486 ]
VOC adsorbent transfer conduit [ 488 ]
solids handling valves [ 490 a & 490 b]
VOC-depleted vapor source [ 492 ]
distribution plate [ 494 ]
support grid system [ 496 ]
heat source [ 498 ]
heat transfer chamber [ 500 ]
heat transfer surface [ 502 ]
vapor bubbles [ 504 ]
gaseous hydrocarbon vapor [ 506 ]
internal cyclone [ 508 ]
freeboard section [ 512 ]cyclone dipleg [ 514 ]
solids handling valves [ 516 a & 516 b]
transfer conduit [ 518 ]
dip tube [ 520 ]
vapor source [ 522 ]
solids handling valves [ 524 a & 524 b]
regen adsorbent transport line [ 526 ]
perforated trays [ 528 ]
level transmitter [ 700 ]
level control valve [ 702 ]
process water [ 714 ]
scrubber spray nozzle system [ 736 ]
scrubber water recirculation piping [ 738 ]
water transfer conduit [ 740 ]
pump suction piping [ 742 ]recirculation pump [ 776 ]
heat source [ 780 ]
heat discharge [ 782 ]
water [ 790 ]
adsorption chamber [ 802 ]
thermal transfer chamber [ 804 ]
feed inlet [ 806 a & 806 b]
product outlet [ 808 a & 808 b]
particulate bed [ 810 ]
thermal transfer chamber inlet valve [ 812 a & 812 b]
inlet valve [ 814 a & 814 b]
product outlet valve [ 816 a & 816 b]
purge inlet valve [ 818 a & 818 b]
depressurization valve [ 820 a & 820 b]
modulating purge valve [ 822 ]
regenerate product line [ 830 ]
oxidant source [ 850 ]
SEQUENCE STEP LIST
[0000]
Syngas Generation [A]
Sequence Step B, Hydrocarbon Reforming [B]
Sequence Step C, Syngas Cooling [C]
Sequence Step D, Solids Removal & SVOC Removal [D]
Sequence Step E, Chlorine Removal [E]
Sequence Step F, Sulfur Removal [F]
Sequence Step G, Particulate Filtration [G]
Sequence Step H, Syngas Compression [H]
Sequence Step I, VOC Removal [I]
Sequence Step J, Metal Removal [J]
Sequence Step K, Ammonia Removal [K]
Sequence Step L, Ammonia Polishing [L]
Sequence Step M, Heat Addition [M]
Sequence Step N, Carbonyl Sulfide Removal [N]
Sequence Step O, Sulfur Polishing [O]
Sequence Step P, Carbon Dioxide Removal [P]
Sequence Step Q, Heat Addition [Q]
Sequence Step R, Steam Methane Reforming [R]
Sequence Step S, Heat Removal [S]
Clean Syngas For End User [T]
Sequence Step B Syngas Inlet [B-IN]
Sequence Step B Syngas Discharge [B-OUT]
Sequence Step C Syngas Inlet [C-IN]
Sequence Step C Syngas Discharge [C-OUT]
Sequence Step D Syngas Inlet [D-IN]
Sequence Step D Syngas Discharge [D-OUT]
SVOC Separation System Control Volume SVOC Discharge [SVOC-OUT]
Sequence Step E Syngas Inlet [E-IN]
Sequence Step E Syngas Discharge [E-OUT]
Sequence Step F Syngas Inlet [F-IN]
Sequence Step F Syngas Discharge [F-OUT]
Sequence Step G Syngas Inlet [G-IN]
Sequence Step G Syngas Discharge [G-OUT]
optional gaesous hydrocarbon source [HC-IN]
Sequence Step H Syngas Inlet [H-IN]
Sequence Step H Syngas Discharge [H-OUT]
Sequence Step I Syngas Inlet [I-IN]
VOC Separation System Control Volume VOC Discharge [VOC-OUT]
Sequence Step I Syngas Discharge [I-OUT]
Sequence Step J Syngas Inlet [J-IN]
Sequence Step J Syngas Discharge [J-OUT]
Sequence Step K Syngas Inlet [K-IN]
Sequence Step K Syngas Discharge [K-OUT]
Sequence Step L Syngas Inlet [L-IN]
Sequence Step L Syngas Discharge [L-OUT]
Sequence Step M Syngas Inlet [M-IN]
Sequence Step M Syngas Discharge [M-OUT]
Sequence Step N Syngas Inlet [N-IN]
Sequence Step N Syngas Discharge [N-OUT]
Sequence Step O Syngas Inlet [O-IN]
Sequence Step O Syngas Discharge [O-OUT]
Sequence Step P Syngas Inlet [P-IN]
Sequence Step P Syngas Discharge [P-OUT]
Sequence Step P Carbon Dioxide Discharge [CO2-OUT]
Sequence Step Q Syngas Inlet [Q-IN]
Sequence Step Q Syngas Discharge [Q-OUT]
Sequence Step R Syngas Inlet [R-IN]
Sequence Step R Syngas Discharge [R-OUT]
Sequence Step S Syngas Inlet [S-IN]
Sequence Step S Syngas Discharge [S-OUT]
Hydrocarbon Reforming Control Volume [B- 1 ]
Syngas Cooling Control Volume [C- 1 ]
Solids Removal & SVOC Removal Control Volume [D- 1 ]
Chlorine Removal Control Volume [E- 1 ]
Sulfur Removal Control Volume [F- 1 ]
Particulate Filtration Control Volume [G- 1 ]
VOC Removal Control Volume [I- 1 ]
Metal Removal Control Volume [J- 1 ]
Ammonia Removal Control Volume [K- 1 ]
Ammonia Polishing Control Volume [L- 1 ]
Heat Addition Control Volume [M- 1 ]
Carbonyl Sulfide Removal Control Volume [N- 1 ]
Sulfur Polishing Control Volume [O- 1 ]
Carbon Dioxide Removal Control Volume [P- 1 ]
SVOC Separation System Control Volume [SVOC- 1 ]
filtration [step 950 ]
filter bundle isolation [step 952 ]
filtrate backflush [step 954 ]
filter cake sedimentation [step 956 ]
filter cake discharge start [step 958 ]
filter cake discharge end [step 960 ]
filtration restart preparation [step 962 ]
Step D1a
Step D1b
Step D1c
Step D1ca
Step D1cb
Step D1d
Step D1e | A system and method for processing unconditioned syngas first removes solids and semi-volatile organic compounds (SVOC), then removes volatile organic compounds (VOC), and then removes at least one sulfur containing compound from the syngas. Additional processing may be performed depending on such factors as the source of syngas being processed, the products, byproducts and intermediate products desired to be formed, captured or recycled and environmental considerations. | 2 |
BACKGROUND OF THE INVENTION
[0001] The present invention relates to an improvement in heat exchanger design, more particularly to thin film distillation systems.
[0002] It is well known in the art to provide a distiller which utilizes the condensation of vapor on one side of a heat conductive plate to provide the heat for evaporation of a liquid on the opposite surface of the plate. In some systems it can often be important to minimize the overall temperature difference through which the process occurs. One method which allows the process to occur without requiring a high temperature differential is to maintain a thin film of liquid on the evaporative side and a minimum film of condensate on the condensing side. This enables the thermal resistance of the films to be minimized.
[0003] Currently used methods include application of liquid with a squeegee such as in U.S. Pat. No. 5,409,576 to Tleimat or liquid application by spraying the film on a rotating disc and allowing condensate removal by centrifugal acceleration such as in U.S. Pat. No. 4,731,159 to Porter et al. Others use gravity as in U.S. Pat. Nos. 4,329,204 and 4,402,793 both to Petrek et al. Though each apparatus has its advantages, each require extensive hardware and fairly large spacing between plates. What is needed is a system which allows the use of compact simple hardware particularly suited to smaller systems.
SUMMARY OF THE INVENTION
[0004] Until the present invention, compact low energy requirement evaporative systems were not practical and thus have not been commercialized. The purpose of this invention is to enable the efficient application of a thin film of liquid to closely spaced heat exchanger surfaces without having to resort to expensive and precise mechanisms. Additionally, an apparatus meeting these requirements should also enable the removal of condensate from closely spaced surfaces without the need to rely upon rotation of the heat exchanger or to require specific orientation of the surface to enable removal of the condensate by gravity.
[0005] A new and non-obvious distillation system which accomplishes these requirements is introduced herein. In its most simplistic form, the invention comprises a pad of resilient material which can hold and move a distilland liquid to be applied by capillary action, and a means to move the pad repeatedly across an evaporator heat transfer surface to apply and renew a thin film of liquid on the surface. The pad is connected to a supply of the liquid, which is continually fed to the surface as it evaporates. In practice the pad is sized to move easily in the gap between two closely spaced corrugations of a surface thus applying liquid to each side of the gap.
[0006] In a preferred embodiment the heat transfer surface is a corrugated cylinder or bellows comprising a thin heat conductive material. A set of pads is aligned to rotate about the axis of the heat exchanger within the outer corrugations forming the heat transfer surface. These pads apply a liquid to be evaporated. Another set of pads, aligned to rotate about the center of the heat exchanger within the inner corrugation serve to remove condensate. This embodiment could be utilized as the heat transfer system of a vapor compression distiller where vapor leaving the outer surface is compressed and introduced to the inside surface which is otherwise sealed from the outside in order to maintain the required pressure differential.
[0007] As such it is an object of the present invention to provide a thin film heat exchanger system which places a thin film of liquid for evaporation on a surface by use of a capillary applicator.
[0008] Another object of the present invention is to provide a heat exchanger utilizing a capillary applicator capable of applying a thin film of liquid between two closely spaced surfaces.
[0009] Still a further object of the present invention is to provide a liquid distiller which operates efficiently and requires minimum energy input into the system to perform.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The novel features considered characteristic of the invention are set forth in the appended claims. The invention itself, however, both as to its construction and its method of operation, together with additional objects and advantages thereof, will best be understood from the following description of the specific embodiments when read and understood in connection with the accompanying drawings.
[0011] [0011]FIG. 1 is a side elevation sectional view of a simplified heat exchanger with a capillary applicator array in accordance with the present invention;
[0012] [0012]FIG. 2 is a top sectional view of the apparatus of FIG. 1 taken through 2 - 2 ;
[0013] [0013]FIG. 3 is a top view of a preferred heat exchanger;
[0014] [0014]FIG. 4 is a side elevation of the FIG. 3 heat exchanger;
[0015] [0015]FIG. 5 is an isometric perspective view of a capillary applicator array used to remove condensate from the inside of the heat exchanger of FIG. 3;
[0016] [0016]FIG. 6 is a top view of a wiper support for use in the FIG. 3 device;
[0017] [0017]FIG. 7 is a side view of the FIG. 6 wiper supports;
[0018] [0018]FIG. 8 is an isometric perspective view of an assembly of wiper supports;
[0019] [0019]FIG. 9 is a top view of a wiper and wiper support in a preferred heat exchanger embodiment;
[0020] [0020]FIG. 10 is a side sectional view of an array of wipers and wire supports of FIG. 9;
[0021] [0021]FIG. 1 is a side elevation sectional view of a representative heat exchanger showing an alternative plate orientation; and
[0022] [0022]FIG. 12 is an end view of the housing of the heat exchanger of FIG. 11.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0023] The preferred embodiments of this invention are mechanisms that allow movable contact between a capillary applicator and a heat exchanger surface with maximum effectiveness and minimum cost. A heat exchanger utilizing this invention can have plates that are more closely spaced than currently allowed with other heat exchangers. The separation between the plates is limited by two parameters. The first being the smallest dimension in which the liquid does not bridge the gap between the plates; and the second being the thickness of the applicator since it needs to accommodate liquid flow as well as physically fit between the plates.
[0024] Looking now more specifically at FIGS. 1 and 2, a simple heat exchanger system designated generally at 1 is depicted. Liquid to be evaporated enters a chamber 3 via an inlet port 5 and collects in a sump 7 . The liquid is absorbed via capillary action by a central capillary 9 and distributed to any number of branch capillaries 11 where it is applied to a heat exchanger surface 13 . Should the sump 7 have excess liquid, an overflow port 15 can be provided to drain said liquid. Although in each preferred embodiment of the invention the capillaries 9 and 11 are preferably wicks comprising woven or non-woven cloth or pads, for the purpose of the invention a capillary applicator could also be a brush, foam pad, a rigid yet porous material, a combination of these, or any other structure so long as the resulting structure can transport liquid by capillary attraction. As such, capillaries 9 and 11 form a capillary applicator array designed to remove liquid from the sump 7 and distribute it on the heat exchanger surface 13 . To enable the applicator array to distribute the liquid, the heat exchanger surface 13 or the capillaries 11 must be moved one with respect to the other. To accommodate this requirement, a rod 17 mountably attached to the capillary applicator array 7 and driven by a driving means (not shown) is made to reciprocate causing the applicator array to move back and forth on the heat exchanger surface 13 . As the liquid is evaporated, vapor can leave the evaporation chamber 3 via a vapor port 19 . In a vapor compression distiller the exiting vapor would be compressed by a compressor (not shown) and then allowed to enter an inlet port 21 leading into a condensing chamber 23 . The vapor entering the condensing chamber 23 now at a slightly higher pressure condenses upon the opposite face of the heat exchanger surface 13 . Condensate leaves via drain port 25 .
[0025] Though the above constitutes a simplified version of the present invention, a more complex version could provide a capillary array which is used in reverse to actually remove liquid from a surface. For instance, a second applicator array could be made to follow the first applicator array. The second array would be utilized to remove excess liquid film thickness after the first applicator array applied the liquid to the evaporative surface. Additionally, a capillary array could even be utilized on the condensate side of the system to remove condensate and allow it to collect in the bottom of chamber 23 . It is of course desirable to utilize the capillary applicator in conjunction with treated surfaces. For instance, it is well known in the art to treat the evaporator side of heat exchanger surface 13 to make it more wettable and to treat the condensation side of heat exchanger surface 13 to reduce wettability resulting in the creation of droplets that cover less surface area and are easier to remove. Though this is a common practice it is a desirable addition from the standpoint that it would increase the efficiency of the system.
[0026] Another preferable embodiment of the present invention is depicted in FIGS. 3 and 4. These FIGs. show a preferred embodiment of a heat exchanger design 27 that is in the form of a bellow shaped cylinder or corrugated tube with outer convolution 29 and corresponding channels 31 forming the evaporator surface and inner convolutions 33 with corresponding inner channels 35 forming the condenser surface.
[0027] [0027]FIG. 5 shows a rotatable assembly of capillary applicators 37 that can be assembled inside heat exchanger 27 to remove condensate. The assembly includes two vertical capillary applicator arrays 39 and 41 positioned diametrically opposite one another. Each array has a number of capillary applicators 43 spaced to fit in every other channel 35 . The two vertical arrays are coordinated so that each channel 35 has a capillary applicator associated with it. In the embodiment depicted, applicator array 39 has an applicator 43 associated with every other channel 35 . Whereas applicator array 41 has an applicator 43 associated with the remaining every other channel 35 . It is intended that the entire assembly 37 can be rotated generally between 10 and 30 rpm inside heat exchanger 27 . This would effectively remove condensation form the surfaces of channels 35 . Each capillary applicator 43 is made to contact vertical holders 45 and 47 so that condensate can be drawn from the applicators 43 to the vertical holder. Each vertical holder contains an additional capillary element which removes condensate from capillary applicators 43 and transports the condensate to a designated region such as a sump. The vertical capillaries can be designed to take advantage of gravity to assist in removing condensate.
[0028] [0028]FIG. 6 shows a capillary applicator support 49 , a series of these are needed to hold applicators 43 . In a preferred embodiment each support is a thin metal or plastic clip approximately 0.005 to 0.020 inch thick that can be snapped into a holder 51 . These holders 51 are best illustrated in FIGS. 7 through 10. Referring to these figures, the capillary material preferably comprises a fabric wick 53 that wraps around a bridge 55 of holder 51 . The wick is held in place by small projections 57 and extend on each side of clip 49 until passing through suitable slots 59 in the holder 51 and wraps around cross piece 61 to pass through another slot and wrap around another support. The wick then is formed from a single piece of material for each subassembly of supports 49 and holder 51 . The support 49 is assembled into holder 51 by sliding it through slots from the backside, the side opposite the extended support.
[0029] In mass production a suitable length of wick material can be extended across the small projection 57 and bridge 55 of the supports, allocated to a holder, at intervals corresponding to the length of wick per support. Then the supports are brought together to a spacing corresponding to the slots in holder 51 as the wick becomes pleated and folds over the supports and the array of supports is pushed through the mounting slots from the back side of holder 51 and snapped into place. This forms an assembly shown in FIG. 9 that can be mounted to a rotatable frame 63 of FIGS. 5 and 10, or frame 65 of FIG. 8.
[0030] [0030]FIG. 8 shows double sets of wicks oppositely mounted to frame 65 . When the assembly is rotated in the channels 31 of heat exchanger 27 there is a leading and following wick moving in each channel 27 This can result in a better liquid film on the surface of heat exchanger 27 . The lead wick can remove residual concentrate from the surface while the following wick applies a new film. An alternative method is to have the leading wick apply excess liquid whereas the following wick removes the excess and spreads a suitably thin film.
[0031] Frame 65 contains a channel 67 that can pick up liquid from a stationary source and facilitate its distribution to the capillary arrays, for example, by means of small bleed ports or by having an end of the wick material submerged in the liquid in channel 67 . In fact, it is desirable to position the channel 67 vertically higher than the wick 53 to better enable flow by utilizing gravity assist.
[0032] [0032]FIGS. 11 and 12 depict an alternative heat exchanger system 69 similar to FIGS. 1 and 2 but oriented so that the channel surfaces 71 are vertical. The disadvantage of this arrangement is its requirement to individually drain each channel via ports 73 so the channels do not become filled with liquid. The advantage is that gravity assists in the flow through the capillary applicators, in this case a single piece of wicking material 75 that follows the corrugations of the heat exchanger and can be supported with structures similar to those in FIGS. 6 - 10 . Another single piece wick 77 is shown on the under side of the heat exchanger and would serve to remove condensate, again assisted by gravity. Wick 75 supplies liquid to the evaporator side of the heat exchanger and would serve to remove condensate, again assisted by gravity. Wick 75 supplies liquid to the evaporator side of the heat exchanger and is shown with liquid container 79 that would contain liquid 81 be picked up by the ends 83 of wick 75 . Container 79 could also supply the wick 75 via small holes 85 and could be part of the wick support structure. | A thin film distiller is provided which applies distilland to an evaporative side by the use of wicks which work by capillary action. The evaporated vapor is transferred to the condensate side after being compressed to a higher pressure where it is condensed and removed by similar wicks. The condensing and evaporating surfaces are formed on opposing sides of a bellows-like sheet of heat conducting material. The sheet would preferably be formed into a cylindrical shape with the evaporative stage on the outside and the condensing stage on the inside of the cylinder. Either the wicks or the heat conducting material are moved with respect to the other such that the wicks place a thin film of distilland on the evaporative surface. Removal of condensate is performed in a similar manner by the wicks in the condensate stage. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority from U.S. Provisional Patent Application Ser. No. 60/981,021, filed on 18 Oct. 2007 and entitled “Goal Achievement Manager” the contents of which are hereby fully incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] Social networking and online advertising.
[0004] 2. Description of the Related Art
[0005] Social networking websites focus on building online communities of people who share interests and activities, or who are interested in exploring the interests and activities of others. These websites have been around since the middle of the nineties but in recent years, social networking has exploded across the web. The Web 2.0 initiative has made modern social networking sites increasingly popular and easier to use than the initial wave of sites that launched in the nineties. As a result, social networking websites are used by hundreds of millions of people around the world nowadays.
[0006] Due to the widespread use and popularity of such websites, a new form of advertising that is growing rapidly is social network advertising. It is online advertising with a focus on social networking sites. Despite of being a relatively immature market, social networking advertising has been growing strongly in recent years as advertisers are willing to take advantage of the information provided by users.
[0007] Thus, there is a need to create new methods of processing and taking advantage of the information input by users in social networking websites. Therefore, the present invention provides an innovative method of monitoring the achievement of goals of users interacting with other users in a social networking website while processing their input data to advertise products or services directed to contribute to the achievement of such goals.
DETAILED DESCRIPTION OF THE INVENTION
[0008] The method consists of using life event data of a website user (hereafter: the “user”) stored on dayboox.com (hereafter: the “website”) to monitor the achievement of user's predetermined goals within a specific timeframe. The user inputs information to the website on past life-events with the desired regularity. This information is organized in a way that allows for creating a digital journal of user's life. In doing so, events occurred in user's life are tracked on the website where they remain indefinitely stored. Complementary, the user inputs information to the website regarding future objectives, aims and goals to be achieved in the short, middle and long term. This information is stored, processed, and managed by the so-called goal achievement manager. Generally, the goal achievement manager allows for storing, sorting, processing user's data and tracking the partial or fully achievement of user's goals.
[0009] Information provided by the user to create the digital journal on the website may comprise any kind of electronic files, like but not limited to, music, videos, images, and photos. The user may also upload information about past life-events through text entries to the website. As explained in the paragraph above, the user not only creates a digital journal on the website but also stores his or her upcoming goals thereon. In this specification, the terms upcoming goal, goal, future objective or aim are used irrespectively and mean the object of a person's ambition or effort, a desired result to be achieved within a specific period of time. The goal achievement manager processes user's information to determine whether user's goals have been partial or fully achieved within a specific timeframe. For this purpose, the goal achievement manager uses the step-by-step goal achievement road application (hereafter: the “goal achievement road”). Therein, each of the single steps or procedures needed to achieve a main goal are showed in a timeline. For example, user's final goal is to acquire real state property consisting of determined characteristics, in a certain area of the city, within a specific period of time. By the way of example only, if the user acquires real state comprising less of the desired characteristics but in the desired area of the city and before the corresponding timeframe expires, the goal is considered partially achieved.
[0010] The goal achievement manager determines when the user fails to perform one or more independent steps proposed in the goal achievement road to achieve the main goal. In this case, the goal achievement manager sends an alarm to the user for the delay or failure to perform such steps. These alarms may consist of, without being limited to, SMSs, emails, or “pop-up” windows showed every time the user logs into the website.
[0011] The goal achievement manager also compares similar goals from different users in a network. This comparison feature is set by the user who has previously joint one or more networks of the website. After joining a network, the user predefines the parameters under which the goal achievement manager should compare his or her goals with another user's goals. The main parameter relates to comparable goals to be achieved within the same timeframe. For example, user A and user B want to acquire a real state property in country C in the middle term. The user may also introduce complementary parameters. One complementary parameter can be user's age. Then, the system compares user A with other users of the same age, or of a similar age group who set the goal of buying real state property in country C in the middle term. Another parameter may be user's occupation. In this example, user A has the same occupation of user B. User A and user B share the common goal of obtaining a salary or income increase within an specific period of time. The goal achievement manager keeps users up-to-date informing when any other of the compared users achieve the goal. If so authorised, the history of the achievement of user's goal may be published in a top list of achievements on the website.
[0012] The goal achievement manager also allows the user to choose among different privacy settings in relation to the information stored on the website. For example, in a highest protection level, the user may decide that very personal goals or goals achievement roads are only viewed by relatives or spouses. Similarly, the history of goals achieved in the past as well as other user's ratings of the achievement of user's goal may be part of a private record only accessed for a limited number of authorised users. The user may also decide to belong to different networks. Each network represents a group of interest. In this case, the goal achievement manager allows the user to decide which information should be shared with users of the network. The lowest protection level is the public record. In this level, any of the website's users are allowed to access the user's information. It should be understood that the privacy protection levels mentioned above are provided by way of example only and that the goal achievement manager may allow the user to choose between several security levels.
[0013] The method allows for searching and collecting data available in the internet that may be relevant to the achievement of user's goals. Generally, the collected data provides guide about how to achieve user's goal(s). It also focuses on keeping the user informed about the latest developments and news related to user's goal(s). For example, if user's goal is to acquire a real state property in a specific country in Europe, the method allows for finding information on the real state market in that specific country. Then, all relevant information is sent to the user like, but not limited to, real state market crashes or bubbles, increase or diminution of interest rates, standard lending conditions in the specific market, etc.
[0014] The method also allows for researching, interpreting, and creating patterns or categorizations of user's goals. For example, goals A, B and C of the user relate to the achievement of victories on sport competitions while goal D relates to learn the use of an specific software application. The method allows for interpreting this data determining a primary interest of the user in sport, and a secondary interest in informatics. Subsequently, the user receives relevant information related to that primary and secondary interest i.e. newsgroups information, blogs information, specialized websites, press articles, etc. Searching of this information focuses on statistically desirable material for example by monitoring bookmarking activities of the website users. The method also allows for using this processed information to advertise products or services considered to be of interest to the user. It should be understood that the interpretation parameter mentioned above is provided by way of example only and that the goal achievement manager may use several parameters when interpreting and processing user's data to send relevant information or advertise products or services.
[0015] Users can comment on another user's life and rate it at different levels of success. The user authorizes to receive another user's comments on his or her achievement's history. If so, a record of the comments can be accessed or deleted at any time. In the same way, a record of past or current ratings can be viewed at anytime on the website. Current ratings are updated in real time.
[0016] Additionally, the user may also request other users to be part of his or her advising network. The user creates an advising network in relation to a specific goal. The network is intended to provide the user with advice consisting of knowledge about how to achieve the specific goal. For example, a law student may create a network of law professionals to obtain advice about how to pass a specific state examination.
[0017] As explained above, aspects of this invention pertain to specific “method functions” to be implemented on computer systems. In an alternate embodiment, the goal achievement manager may be implemented as a computer program product for use with web services similar to dayboox.com. | The present invention relates to a method for controlling, planning, managing and enhancing the progressive achievement of user's future goals. The method allows for comparing and interpreting life-event data provided by the user in connection with his or her expected future achievements within a specific timeframe. It also enables ecommerce opportunities for sponsors and advertisers. | 6 |
CROSS-REFERENCES TO RELATED APPLICATIONS
This application is the U.S. National Stage of International Application No. PCT/DE2011/002057, filed Nov. 23, 2011, which designated the United States and has been published as International Publication No. WO 2012/072066 and which claims the priority of German Patent Application, Serial No. 10 2010 053 154.5, filed Nov. 26, 2010, pursuant to 35 U.S.C. 119(a)-(d).
BACKGROUND OF THE INVENTION
The invention relates to a movement lock for a locking element or an actuator in a locking system.
Lock cylinders, which not only have a mechanical structure, oftentimes include actuators that affect certain adjustment or blocking members within the lock cylinder and interact with these. This can, for example, involve a rotation or displacement of a component, such as a locking bar or a locking function to prevent rotation or displacement of the component.
This is based on the supposition that each component has, of course, a certain mass, which may potentially be caused to move as a result of physical energy in the locking system, like vibrations or an external pulse application, so that the function that should be realized for example during blocking of a rotation or movement, is no longer effective.
SUMMARY OF THE INVENTION
It is therefore an object of the invention to provide a solution that prevents an undesired or inadvertent movement of a locking element or an actuator.
This object is achieved according to the invention with a movement lock for a locking element or an actuator in a mechanical or mechatronically actuatable locking system, which is characterized in
that the movement lock has a blocking element which can be brought into engagement with the locking element or actuator by a system which is maintained under tension or caused to move and can be triggered as a result of an external pulse application on the locking system.
Preferably, the blocking element can be brought temporarily into engagement with the locking element or actuator and can be reset by the legitimate actuation of the locking system.
Structurally, this movement lock can be designed in various ways, with preferred embodiments being set forth hereinafter.
According to one configuration, the blocking element includes a unilaterally supported pivot lever having a free end provided with a section or stop which can be brought into engagement with the actuator to lock its movement, and a tension spring which has one end connected to the pivot lever at a distance to the pivot lever bearing and another end being supported at a distance to the pivot lever bearing and offset thereto, and which is oriented and adjusted such that the pivot lever assumes an intermediate position when the tension spring is aligned substantially in prolongation of the pivot lever axis, in which position the spring is tensioned and is relaxed in deflections that are mirror images of one another, with one of the deflections of the pivot lever representing the rest or release position and the other deflection of the pivot lever representing the locking position, and with the pivot lever being swingable when released from the intermediate position into the locking position.
When the movement lock is intended for temporarily blocking the rotation of an actuator having a plurality of components, it is provided that one of the components of the actuator is an electrically-operated rotary lock which can be brought into engagement with a locking bar acting in a lock cylinder between a cylinder core and a cylinder housing in order to prevent a rotation of the cylinder core when a key has a wrong encoding, wherein the stop for the pivot lever remains in the rest or release position, when the lock cylinder is actuated in a normal way, and swings into the locking position in the presence of an external pulse application upon the components to prevent the movement of the rotary lock.
A mass, preferably a ball, can hereby be brought into contact with the pivot lever and is freely movable in a recess associated thereto and applies a momentum upon the pivot lever, when the pivot lever is acted upon by a pulse in its rest or release position so as to move the pivot lever away from the rest or release position into the locking position.
It is further provided that the pivot lever can be moved from the locking position via the intermediate position back to the rest or release position, when an authorized key for operating the locking system is withdrawn to thereby apply a momentum upon the pivot lever.
According to a further configuration, the rotor shaft of the actuator has a section which widens in a substantially rectangular manner in the manner of a cam and is rotatable between the opposing legs of a U-shaped reset frame, wherein the reset frame is freely movable in perpendicular relationship to the rotor shaft and one of the legs of the reset frame is able to bear upon one of the sides of the rectangular section by its own weight or by action of a spring, so that a free rotation of the rotor shaft can be prevented.
Viewed in direction of the rotor shaft, the section may hereby have two flat longitudinal surfaces disposed in confronting relation and connected in the shape of an arc by two transverse surfaces, wherein one of the legs of the reset frame rests upon the one longitudinal surface of the section, when the rotor shaft assumes the idle rotation position.
Another embodiment of the movement lock is characterized in that the locking element is a locking bar which acts between a cylinder core and a cylinder housing in a lock cylinder to prevent rotation of the cylinder core, when a key has the wrong encoding, and to liberate it when operation of the locking system is legitimate,
wherein a pin is provided which is movable in relation to the locking bar, especially axially movable, and designed as blocking element, and which does not interfere in its rest position with the movement of the locking bar but is shifted axially when acted upon by an external pulse and prevents the movement of the locking bar by way of non-corresponding contact surfaces, with the rest position of the blocking element being retained by a retaining element which is displaceable transversely in relation to the blocking element, and with the retaining element being axially removable away from the blocking element by the pulse application in opposition to the force of a spring to thereby allow axial displacement of the blocking element.
In this context, it is further provided that in the presence of a legitimate locking when a key is inserted, a lever pin causes both the movement of the rotary lock to clear the movement of the locking bar and implementation of a displacement of the blocking element accompanied by a displacement of a coupling element, wherein the rest position of the blocking element is maintained by the retaining element in which rest position the non-corresponding support surfaces are in a position disengaged from the locking bar.
BRIEF DESCRIPTION OF THE DRAWING
The invention will now be explained in more detail with reference to the drawings. It is shown in:
FIG. 1 : schematically a part of a locking system, and more particularly the locking bar cooperating with the actuator in the normal locking condition,
FIG. 2 : the state that enables a locking,
FIG. 3 : the state when the movement lock is triggered,
FIG. 4 : the additional locking element in the form of a reset frame, and
FIGS. 5-8 : another embodiment in various views and states.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
In a locking system, not shown in detail, an electrically driven actuator 1 is provided for example in a lock cylinder housing 21 in which a cylinder core 22 is rotatably arranged, in which a not shown key can be inserted.
When an electronically encoded key is used in this locking system, an electrical signal to the actuator is transmitted in the presence of a matching key to cause the rotor shaft 2 to rotate into a position in which the locking bar 13 is released so that the latter is able to move radially inwardly, to emerge from the recess 23 , and thus to clear the parting plane between the lock cylinder housing and cylinder core in a customary manner, thereby executing a locking process.
Vibrations or in particular an external pulse, for example a blow, could cause a slight rotary motion of the rotor shaft, even though the actuator is deactivated in the absence of a matching key.
In the worst case scenario, this may be sufficient to also liberate the locking bar or to permit an actuation, i.e. an unlocking operation could be executed.
According to the invention, as shown by way of an embodiment in FIGS. 1 to 3 , a pivot lever 3 is provided, which is maintained under tension by a spring 4 .
The spring 4 has a free end connected to the pivot lever 3 at its free end provided with a stop 10 and another end supported at a distance to a pivot lever bearing 11 and offset thereto.
In order for the pivot lever to be able to move and still being maintained under spring tension, the support for the pivot lever 3 and the spring 4 is slightly offset relative to one another.
It is essential that the spring 4 in the position shown in FIG. 1 , the so-called rest or release position, is tensioned. Also, the spring is tensioned in the locking position which is shown in FIG. 3 . The pivot lever has to overcome between these two positions a position in which the spring is slightly more tensioned.
As a result of an external pulse application, the pivot lever is moved from the rest or release position ( FIG. 1 ) in such a way as to overcome the intermediate position and to swing into the locking position ( FIG. 3 ).
This swinging motion past the intermediate position can be assisted by a freely moving ball 5 having a mass which is caused to move in response to a pulse from any direction and presses against the pivot lever, as shown in FIG. 3 .
An additional safeguard against rotation of the actuator may also be realized by a so-called reset frame 7 .
For that purpose, the rotor shaft 2 is provided with a wider section 6 in the manner of a cam.
As shown in FIG. 4 , this section 6 is embraced by the reset frame 7 which has a U-shaped configuration.
The reset frame 7 is freely movable in perpendicular relationship to the rotor shaft 2 .
Since having, of course, an—albeit slight—mass, the reset frame will assume, due to gravity, the lowest position—with respect to its freedom of movement—as shown in FIG. 3 . It may also be held by a spring in this preferred position.
Since the section 6 , configured in the manner of a cam, on the rotor shaft is substantially rectangular in shape, the reset frame bears with its one, in this case, upper leg 8 , upon the upper longitudinal surface 9 so that the weight or mass of the reset frame secures the rotor shaft in this position, and pushes the weight or mass back in the presence of an external pulse as a result of the shape of the section 6 .
FIGS. 5-8 illustrate a further embodiment, with FIGS. 6 and 8 each showing a different view of the state shown in FIGS. 5 and 7 respectively.
Not shown in these figures is the lock cylinder whereas the locking bar acting again in a known manner between the latter and the cylinder core is designated by 13 .
The locking bar 13 interacts hereby again with an electrically-operated actuator 1 , i.e. when the electrically-operated actuator 1 is actuated with the rotary lock 12 , the locking bar 13 , depending on design, can be moved away from the position in which it locks the locking system and release the locking position or the electrically-operated actuator can be brought again with the rotary lock 12 into the position in which the locking bar 13 cannot be moved.
In this embodiment, a pin serving as blocking element 14 is provided which is spring-biased (spring 19 ) and axially (with respect to its longitudinal axis) shiftable ( FIG. 5 ). This pin has, as shown in FIG. 8 , vacuum recesses 15 which enable a radial mobility of the locking bar 13 depending on the axial position of the pin 14 .
When assuming the axial position in which the radial movement of the locking bar is cleared, this pin is held by a retaining element 17 —in this case a ball maintained under pressure by a spring ball 9 ( FIG. 6 ).
When the locking system is acted upon by an external pulse, the retaining element 17 is axially displaced to the position shown in FIG. 8 , thereby relaxing the spring 19 . It can be seen that the locking bar cannot move radially due to the support in the upper recess so that the lock cylinder is blocked, i.e. no unlocking operation can be executed.
When inserting a key, not shown here, the lever pin 16 is turned and clears the coupling element 24 which is maintained under the pressure by a spring 20 .
This coupling element 24 in turn presses—in opposition to the pressure of spring 19 or the retaining element 17 —the blocking element 16 designed as pin, back into the starting position shown in FIG. 6 . | The invention relates to a movement lock for a locking element or an actuator in a locking system which can be operated in a mechanical or mechatronic manner. Provision is made here for the movement lock to have a blocking element which can be brought into engagement with the locking element or actuator by a system which is maintained under tension or caused to move and can be triggered as a result of an external pulse application on the locking system. | 4 |
CROSS-REFERENCE TO RELATED APPLICATION
The present application is a divisional of application Ser. No. 08/694,541, filed Aug. 9, 1996, now U.S. Pat. No. 5,808,366, issued Sep. 15, 1998.
FIELD OF THE INVENTION
This invention relates to semiconductor integrated circuits and methods of designing and fabricating same, and more particularly to packaging methods for integrated circuits and methods of designing and fabricating same.
BACKGROUND OF THE INVENTION
Integrated circuits are widely used in consumer, commercial and military applications. As is well known to those having skill in the art, an integrated circuit generally includes a semiconductor die which is potted with a potting material.
More specifically, a plurality of integrated circuits are generally formed on a semiconductor wafer using diffusion, epitaxial growth, ion implantation, deposition, photolithography and many other conventional processes, to fabricate a plurality of microelectronic devices in a microelectronic substrate. A plurality of patterned conductive interconnect (wiring) layers of conductive lines are fabricated on the microelectronic substrate, separated by insulating layers. The conductive layers are generally polysilicon, metal or alloys thereof and the insulating layers are generally silicon dioxide, silicon nitride or other insulating layers.
The wafer is then diced into chips, also referred to as semiconductor dies. The dies are then fixed onto lead frames and wire bonded to produce electrical connections between bonding pads on the die and the leads in the lead frame.
Then, the die and lead frame are potted with a potting material such as a potting compound resin. The potting material protects the semiconductor die from external effects, such as moisture and mechanical shock. The potting material may also help to transfer heat from the semiconductor die, and also electrically insulates the semiconductor die. To perform these functions, the potting compound resins generally have a relatively high permittivity.
Unfortunately, the potting material which covers the semiconductor chip or die may produce a parasitic capacitance between the patterned conductive interconnect lines. For example, when a potting compound such as plastic, ceramic or other resins is formed on the semiconductor die, and penetrates between the conductive regions such as metal lines in the outer layer of the integrated circuit, the potting compound may increase the parasitic capacitance.
As the integration density and the length of the conductive lines in an integrated circuit increase, this increase in parasitic capacitance may produce problems. For example, the performance of the drivers which drive the conductive lines may deteriorate, and the overall operation of the integrated circuit may degrade because the drivers have to drive larger parasitic capacitance than expected.
One technique for solving these problems is described in a publication by Luu T. Nguyen et al. entitled "Effects of Die Coatings, Mold Compounds, and Test Conditions on Temperature Cycling Failures", IEEE Transactions on Components, Packaging and Manufacturing Technology, Part A, Vol. 18, No. 1, March 1995, pp. 15-22. In this publication, an additional protective layer is coated on the integrated circuit, between the patterned conductive interconnect layers and the potting compound. However, the need to form an additional protective layer may increase the cost of the integrated circuit.
SUMMARY OF THE INVENTION
The present invention designs and fabricates integrated circuits including a semiconductor die which is potted with a potting material, by designing and fabricating the semiconductor die to take into account the capacitive effect of the potting material on the performance of the semiconductor die. Accordingly, operating speed of the integrated circuit may be increased, without the need to add additional protective layers, by designing and fabricating the integrated circuit to include the expected increase in parasitic capacitance by the potting material in the design of the integrated circuit itself.
In particular, according to one aspect of the present invention, the semiconductor die includes a plurality of drivers which drive patterned conductive lines at the outer surface of the semiconductor die. The semiconductor die is designed and fabricated by designing and fabricating at least one of the drivers to drive the patterned conductive lines at the outer surface of the semiconductor die, as capacitively loaded by the potting material. According to another aspect of the invention, at least one repeater is designed and fabricated along at least one of the patterned conductive line, to drive the patterned conductive lines at the outer surface of the semiconductor die, as capacitively loaded by the potting material.
In another aspect of the present invention, intelligent drivers may be designed and fabricated in the integrated circuit, to sense the load on at least one of the patterned conductive lines at the outer surface of the semiconductor die, as capacitively loaded by the potting material, and to drive the patterned conductive line at the outer surface of the semiconductor die as capacitively loaded by the potting material.
In yet another aspect of the present invention, the thickness of one or more insulating layer which insulates the conductive interconnect layers from one another is expanded on the outer patterned conductive interconnect layer to fill the spaces between the plurality of conductive regions in the outer patterned conductive layer. The potting material thereby does not extend between the plurality of conductive regions in the outer patterned conductive layer. However, a separate die protective layer as described in the prior art is not required.
An integrated circuit according to the present invention includes a semiconductor die and a potting material on the semiconductor die. The semiconductor die is operatively optimized to take into account the capacitive effect of the potting material on the semiconductor die. In one embodiment, the semiconductor die includes a plurality of conductive lines and at least one driver which drives at least one of the conductive lines. The drivers are sized to drive to conductive lines, as capacitively loaded by the potting material. In another aspect of the invention, at least one repeater is electrically connected to at least one of the plurality of conductive lines to drive the at least one conductive line as capacitively loaded by the potting material.
In another aspect, an integrated circuit includes means for sensing a capacitive load on the patterned conductive lines of the outer surface of the semiconductor die, as capacitively loaded by the potting material. The integrated circuit also includes means, responsive to the sensing means, for driving the patterned conductive lines at the outer surface of the semiconductor die, as capacitively loaded by the potting material.
In integrated circuits, and designing and fabricating methods according to the present invention, the capacitive effect of the potting material on the semiconductor die may be taken into account by calculating parasitic capacitances for the conductive lines according to the following relationships: ##EQU1## ε p is the permittivity of insulating layers covering said plurality of conductive lines,
ε m is the permittivity of the potting material,
d 1 is the distance between an adjacent pair of conductive lines,
d 2 is the distance between the top portions of the adjacent pair of conductive lines,
d 3 is the thickness of the insulating layer covering the conductive lines,
L is the length of a conductive line, and
H is the height of the conductive line and half the width of the conductive line. High speed integrated circuit devices may thereby be provided notwithstanding the use of high permittivity potting materials to pot the integrated circuit.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional view of a CMOS integrated circuit including a microelectronic substrate, a plurality of patterned conductive interconnect layers and a potting material.
FIG. 2 is a schematic diagram illustrating modeling of parasitic capacitance between conductive lines.
FIGS. 3A and 3B are equivalent circuit diagrams for calculating parasitic capacitance in the model of FIG. 2.
FIG. 4 graphically illustrates an increase in the ratio of parasitic capacitance when the permittivity and width of a potting compound is changed.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The present invention now will be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. In the drawings, the thickness of layers and regions are exaggerated for clarity. Like numbers refer to like elements throughout.
The present invention provides integrated circuits with improved operating speed by calculating the parasitic capacitance generated in a conductive line, referred to hereinafter as a "metal line" by a potting material, and by analyzing the calculated parasitic capacitance to reduce the parasitic capacitance of the metal line or to increase the driving capability of the metal line.
As will be described in detail below, according to one aspect of the present invention, an integrated circuit includes a plurality of microelectronic devices in a microelectronic substrate and a plurality of metal lines on the semiconductor substrate. A passivation layer covers the plurality of metal lines to a sufficient thickness so as not to be filled with the potting material between the plurality of metal lines.
According to another aspect of the present invention, an output driver which drives the metal lines has sufficiently large driving capability to drive the metal lines notwithstanding the increase in the load by the parasitic capacitance caused by the potting compound material. According to another aspect of the invention, an intelligent driver is provided including a load detector which detects the amplitude of the load caused by a parasitic capacitance on a metal line and an output driver which is responsive to the load detector, having a driving capability which is set in response to the detected output of the load detector.
According to yet another aspect of the present invention, repeaters are formed in the semiconductor substrate at predetermined lengths along at least some of the metal lines to drive the metal lines notwithstanding the increase in parasitic capacitance.
Referring now to FIG. 1, there is illustrated a cross-sectional view of a conventional CMOS integrated circuit. On the surface of a silicon or other substrate 10, a P-type well 12, an N-type well 14, a field oxide layer 16, a gate oxide layer 18, a gate electrode 20, a sidewall spacer 22 and a source/drain region 24 are formed by a typical CMOS manufacturing process to define a transistor. Then, a first planarized insulating layer 26 is formed, and a contact is formed to the source/drain region 24 of the transistor to make a source/drain electrode to a first metal line 28. Thereafter, the first metal line is covered by a second planarized insulating layer 30, and a second metal line 32 is formed on the second planarized insulating layer 30. Then, the second metal line 32 is covered by an outer insulating layer, also referred to as a passivation layer, including a PSG (phosphosilicate-glass) layer 34 and an SiN layer 36, and the passivation layer is covered by a potting compound material 38.
As shown in FIG. 1, in a semiconductor package device fabricated as described above, a recess or space 40 is formed between the second metal lines 32. The recess 40 is filled with the potting compound material 38.
Since the dielectric constant of the potting compound material 38 is greater than that of air which is "1", the parasitic capacitance on the second metal line 32 is increased. Accordingly, a parasitic capacitance larger than an intrinsic parasitic capacitance C interline between the metal lines is generated, and acts as an unexpected parasitic load. Therefore, the output buffer which is designed to drive the intrinsic parasitic capacitance may not operate properly. According to the invention, solutions for this problem are provided.
FIG. 2 is a diagrammatic view of the interline capacitance between the metal lines. Referring now to FIGS. 1 and 2, the parasitic capacitance between the metal lines is caused by two primary contributors.
First, there is a parasitic capacitance which is generated when an electric field is created in the closest distance d 1 between the metal lines. In this case, the permittivity is measured at the PSG layer 34 and is designated by ε p . The parasitic capacitance is represented by C interline as a common parasitic capacitance.
Second, there is another parasitic capacitance generated by a distance d 2 which passes through the PSG layer 34 and the SiN layer 36 and enters the potting compound material. This parasitic capacitance is taken into account according to the present invention. The permittivities of the PSG layer and the SiN layer are designated by ε p , and the permittivity of the potting compound material is designated by ε M . Since the PSG layer and the SiN layer are similar to each other, their permittivities are nearly the same and therefore commonly designated by ε p .
FIGS. 3A and 3B are equivalent circuit diagrams for calculating the parasitic capacitance of the modeling structure of FIG. 2. When the thickness of each passivation layer of the PSG and the SiN layers is designated by d 3 , each parasitic capacitance can be calculated from the following equations: ##EQU2## where C 4 is an intrinsic parasitic capacitance which is not influenced by the potting compound material, and other parasitic capacitances are values which are increased by the potting compound material. The total parasitic capacitance can be calculated from the following equation, and is increased by the second term when compared to the intrinsic parasitic capacitance C 4 : ##EQU3##
When equations (1), (2) and (3) are substituted into equation (4), the total parasitic capacitance is represented by the following equation: ##EQU4## the total parasitic capacitance is finally represented by the following equations: ##EQU5## where K pot is a constant which indicates a parasitic capacitance increased by the potting compound material, when compared to the intrinsic parasitic capacitance.
The variation of the parasitic capacitance can be seen by graphically illustrating K pot based on the above equations. In most cases, neglecting slight differences, p is about 0.5. Assuming that q and r are the X-axis and Y-axis, respectively, the resulting graph is shown as in FIG. 4.
Referring to FIG. 4, it can be seen that the total parasitic capacitance increases with a decrease in q and r. That is, the thicker the potting compound material is compared to the PSG and SiN layers, and the larger the permittivity of the potting compound material compared to the PSG layer, the more K pot is increased.
Assuming that the thickness and permittivity of the potting compound material are increased by a factor of 10, the total parasitic capacitance is increased by a factor of 3, as shown in FIG. 4. However, the total parasitic capacitance is generally increased by a factor of about 1.3 to about 2.
According to the invention, the parasitic capacitance of the potting compound material may be reduced by increasing the thickness of the PSG layer, to thereby reduce the amount of the potting compound material which is extends between the metal lines. Note that to fill the PSG layer to a sufficient height, an oxidation process may need to be implemented for a long time, and the bottom layer or the passivation layer may be adversely impacted.
According to another aspect of the invention, a large and powerful driver is designed and fabricated, to drive a load larger than that conventionally designed and fabricated for an output stage.
According to another aspect of the invention, an intelligent driver capable of actively sensing the load of the output stage can be designed and fabricated. The intelligent driver can adjust its performance by sensing the magnitude of the load of the output stage. Specifically, a load detector detects the magnitude of the load generated by the parasitic capacitance of each metal line. An output driver includes a driving capability which is set in response to a detected output of the load detector.
Finally, the length of conductive lines such as output buses can be limited, to limit the capacitance. If long lengths are required, a level repeater can be inserted in the conductive lines so as not to drive a large load.
In the drawings and specification, there have been disclosed typical preferred embodiments of the invention and, although specific terms are employed, they are used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention being set forth in the following claims. | High speed integrated circuits are designed and fabricated by taking into account the capacitive loading on the integrated circuit by the integrated circuit potting material. Line drivers may be sized to drive conductive lines as capacitively loaded by the potting material. Repeaters may be provided along long lines, to drive the lines as capacitively loaded by the potting material. Intelligent drivers may sense the load due to the potting material and drive the lines as capacitively loaded by the potting material. The thickness of the passivating layer on the outer conductive lines may also be increased so as to prevent the potting material from extending between the conductive lines. High speed potted integrated circuits may thereby be provided. | 7 |
FIELD OF THE INVENTION
[0001] The present invention relates to instruments for endodontic use, and more particularly to apparatuses and associated methods for performing root canal treatment.
BACKGROUND OF THE INVENTION
[0002] In endodontics it is necessary to thoroughly debride a root canal (or pulp chamber) of a tooth, in order to reduce the chances of bacterial growth in the root canal, and to improve the healing potential of the remaining healthy tissue. As used herein, debridement includes for example, the removal of dead, damaged, or infected tissue of the dental pulp, as well as hypercalcification, residual resistant paste, various constrictions, broken instruments, and fragments or foreign material lodged in the root canal.
[0003] This debridement would ideally terminate at the apical foramen. The apical foramen is the opening at the apex of the root of the tooth, through which the nerve and blood vessels that supply the dental pulp pass. The dental pulp resides in the root canal and is comprised of living circulatory, connective, and nerve tissues.
[0004] As part of the endodontic therapy, and following the debridement of the root canal, the endodontic clinician shapes the root canal prior to inserting a filler material in place of the original dental pulp.
[0005] To this end, hand (i.e., manual) files and rotary files (i.e., electrically operated) commonly called spiral instruments are used for the treatment of root canals. Typically, these spiral instruments have a generally triangular, square, or rectangular cross section, and comprise edges (or corners) that attack the dental wall and strike the dentine wall at an acute angle. Consequently, these conventional files have a tendency to wear out prematurely and to break.
[0006] In addition, these conventional files may bind when resisted by obstacles and eventually break inside the root canal, as they do not have a sufficient thickness to resist torsion fatigue induced thereon. Moreover, such files do not generally perform a complete rubbing of the dental wall in order to achieve a hermetic obturation of the root canal, thus yielding to a risk of infection.
[0007] In addition, the tip of these spiral instruments is usually a non-cutting tip based on the assumption that a cutting tip will facilitate the formation of false canals.
[0008] Conventionally, withdrawing segments of fractured instruments that cause root obstructions, was done by means of ultrasonic files. An exemplary technique requires the use of conventional manual files from No. 8 to 15 having a taper of 2%, in order to open a cutting around the lodged segment of the fractured instrument. However, this withdrawal technique involves the risk of introducing additional breakage of the newly used instrument, as well as opening false canals. As a result, this conventional technique has not generally yielded optimal results.
[0009] Furthermore, in order to overcome obstructions resulting from hypercalcification, certain conventional treatment methods propose the enlargement of the root canal using files from No. 8 to 15 having a 2% taper, or C+ files followed by the use of rotary files (electrically operated) from No. 10 to 25 with a 2%, 4%, or 6% taper. However, this method also does not provide optimal results and introduces the risk of breakage of the newly used file, as well as opening false canals.
[0010] The weakness of the conventional endodontic files in fracture or in procedural errors, is due to their cyclic fatigue and torsional stress, and the difficulties of removing the broken files, as explained in the following publications:
Bahcall J K, et al., “The causes, prevention, and clinical management of broken endodontic rotary files,” Dent Today. 2005 November; 24(11):74, 76, 78-80; quiz 80, Department of Surgical Sciences, Marquette University School of Dentistry, USA, the abstract of which is available online at http://www.ncbi.nlm.nih.gov/pubmed/16358801. Peters O. A., “Rotary Instrumentation: An endodontic perspective,” American Association of Endodontists, Winter 2008, which is available online at https://www.aae.org/uploadedfiles/publications_and_research/endodontics_colleagues_for_excellence_newsletter/winter08ecfe.pdf. This publication makes it clear that not all root canals lend themselves to rotary preparation, due to varying degrees of the clinicians' skills and case complexity, and to the fact that rotary files may fracture rather unexpectedly or create procedural errors.
[0013] The following references clarify that the fracture of an endodontic file may cause the endodontic treatment to have a lower success rate, and that fragments of files may be removed using a retrieval system; however, this procedure can be technically demanding, and several fragments may be left in-situ:
Metzger, Z. et al., “The Self-Adjusting File (SAF). Part 1: Respecting the Root Canal Anatomy—A New Concept of Endodontic Files and Its Implementation,” Journal of Endodontics 36 (4): 679-90 (2010). De-Deus, G. et al., “The Self-Adjusting File Optimizes Debridement Quality in Oval-shaped Root Canals,” Journal of Endodontics 37 (5): 701-5 (2011). Siqueira Jr., J. F., et al. “Ability of Chemomechanical Preparation with Either Rotary Instruments or Self-Adjusting File to Disinfect Oval-shaped Root Canals,” Journal of Endodontics 36 (11): 1860-5 (2010).
[0017] Although cylindro conical instruments have been used by dentists only in root canal filing material (spreaders) with a smooth surface, they have not been used to probe, shape, debride, catheterize, penetrate or bypass obstacles in root canal treatments. Reference is made to Carrotte, P., “Endodontics: Part 5 Basic instruments and materials for root canal treatment,” British Dental Journal 197, 455-464 (2004), Published online: 23 Oct. 2004, at http://www.nature.com/bdj/journal/v197/n8/full/4811738a.html Root canal filling instruments.
[0018] In addition to the risks involved with the use of conventional treatment methods, there is a potential for damaging the apex or causing a shear in the coronal part or in the apical part of the root canal.
[0019] Yet another disadvantage of the conventional treatment methods is that the instruments generally cannot penetrate difficult hypercalcifications, blockages, and narrow canals, nor can they probe the ledges or pierce the most resistant residual paste in the root canal.
[0020] In addition, they cannot bypass lodged segments of fractured instruments in the root canals, nor can they remove dental plugs. Moreover, they cannot penetrate blockages resulting from root canal treatment, nor can they penetrate the obliterated coronary infundibula due to the high fracture risk.
[0021] Still another disadvantage of the conventional treatment methods is that the instruments generally may not be totally suitable for use under elevated torque or high speed, due to the high fracture risk. In addition, the spiral instruments generally exert force on the dental wall and are therefore subjected to a reactive force. In fact, rubbing the dental wall does not facilitate penetration in the desired direction of the dental apex.
[0022] Wherefore, there still remains an unsatisfied need for new endodontic instruments and associated methods of use for performing better root canal treatment. These instruments should penetrate or bypass most, if not all blockages in the root canals, while achieving optimal root canal treatment with optimal root canal shape, in order to maximize irrigation and hermetic obturation of the root canals.
SUMMARY OF THE INVENTION
[0023] The present invention satisfies this need, and presents several preferred designs for endodontic instruments and associated methods of use for performing root canal treatment. These instruments penetrate or bypass most, if not all blockages in the root canal, while achieving optimal root canal treatment with optimal root canal shape, in order to maximize irrigation and hermetic obturation of the root canal.
[0024] In addition, the treatment of a root canal with the instruments and methods of the present invention, while avoiding damage to either the root canal or the apex, is ensured a very high rate of success.
[0025] Although the teeth and grooves of the endodontic instruments of the present invention may become worn with use, they will not easily break because they do not attack the radical dentine at weak pointed angles. In addition, the use of sandblasting to form the endodontic instrument helps to avoid corrosion of instrument resulting from stocking, storage, or usage.
[0026] The various instruments of the invention surpass the conventional stainless steel hand files and the NiTi rotary instruments, and present numerous advantages among which are the following:
[0027] The instruments are very flexible so that they may follow difficult curved root canals without damaging the apex, making a false canal, or causing a shear in the coronal part and the apex of the root canal.
[0028] They penetrate the difficult hypercalcifications, obstructions and narrow canals.
[0029] They probe the ledges of the root canal.
[0030] They pierce residual, resistant pastes.
[0031] They bypass fractured files, lentulos, posts, and fractured silver cones.
[0032] They do not create false canals, shears and dental plugs.
[0033] They allow the removal of pre-existing dental plugs.
[0034] They penetrate blockages caused by an inadequate use of other instruments.
[0035] They penetrate the obliterated coronary infundibula with low risk of fracture or of damaging the apex.
[0036] Furthermore, these instruments successfully perform and facilitate the complete endodontic procedure:
[0037] They penetrate root canals that other endodontic instruments fail to penetrate.
[0038] They resist increased torque and high speeds (ranging from approximately 1.5 N to 5 N and from approximately 300-600 rpm) due to their high resistance.
[0039] Their success in treating and retreating root canals helps to avoid expensive and painful endodontic surgeries and eventually implants in case of failure of endodontic treatments.
[0040] To this end, each instrument of the present invention comprises a handle that secures an elongated tapered shank. The shanks of the instruments include cylindro-conical files having a circular cross section, which penetrate the root canals using most, if not the entirety of their peripheral surfaces, thus providing a better ability to resist torsion fatigue, to preserve the initial circular dental canal anatomy, and to attain a hermetical obturation of the root canals. The shanks can assume a variety of designs based on a combination of characteristics, including but not limited to: a roughed surface, a cutting surface, a smooth area, a conical cutting tip, a non-cutting tip, a beveled tip, and a non-beveled tip.
[0041] Based upon the various designs of their shanks, the endodontic instruments may generally be categorized, as follows:
1 st Category: Instruments for catheterization and for passing through root obstacles. 2 nd Category: Instruments for fine and curved roots. 3 rd Category: Instruments that may be used for enlarging and shaping root canals.
[0045] The instruments in the 1 st Class of the 1 st Category can be either hand operated or electrically rotating. Each of these instruments includes a lateral surface that contains a number of superficial horizontally, vertically, or transversally striated grooves that define slightly cutting edges, and that are either separated by smooth areas or sandblasted areas. The instruments in this class include a generally circular cross-section, and a conical tip that may be cutting or non-cutting, beveled or non-beveled. These instruments include hand operated files for root canal treatment that are preferably made from stainless steel (with nos. ranging from 10 to 25) or NiTi (with nos. ranging from 20 to 25) and electrically rotating NiTi files (with nos. ranging from 10-to 25), all with a taper of approximately 0, 1, 2, 3, or 4% and a length ranging from approximately 12 mm-32 mm.
[0046] The instruments in the 2 nd Class of the 1 st Category are hand operated instruments having a series of horizontally, vertically, or transversally striated deep grooves with cutting edges, that are separated by restricted smooth or sandblasted areas or even instruments that are completely sandblasted. The instruments in this class include a generally circular cross section, and a conical tip that may be cutting or non-cutting. The shanks of these instruments range from No. 6 to 20. The shanks may be made from stainless steel, and range from No. 6 to 20. The shanks may alternatively be made from NiTi, and range from No. 20 to 40. The shafts of all these instruments have a taper of approximately 0%, 1%, 2%, and 4%, and a length that ranges from approximately 12 mm to 32 mm.
[0047] The instruments of the 2 nd Category preferably include electrically operated rotating NiTi instruments, each having a tapered shank with a series of transversal, deep, striated grooves with cutting edges. In other embodiments can alternatively, the instruments include a series of horizontally or vertically striated, deep grooves with cutting edges, that are separated by either smooth or roughened (i.e., sandblasted) restricted areas. These instruments include electrically rotating files for root canal treatment with nos. 10 to 20, and having an approximate 2% taper and a length ranging from approximately 21 mm to 32 mm.
[0048] The instruments of the 3 rd Category preferably include electrically operated rotating instruments, each having a shank with a generally circular cross section and a conical cutting or non-cutting tip, with a series of saw teeth that are separated by restricted smooth areas. In other embodiments, the shank can include horizontally, vertically, or transversally striated grooves. These instruments include electrically rotating files for root canal treatment with nos. ranging from 20 to 40, and having an approximate 4% to 10% taper and a length ranging from approximately 21 mm to 32 mm.
[0049] The endodontic procedure being administered determines the selection of the category, the instruments within each category, and the sequential use of the selected instruments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0050] The various features of the present invention and the manner of attaining them will be described in greater detail with reference to the following description, claims, and drawings, wherein reference numerals are reused, where appropriate, to indicate a correspondence between the referenced items, and wherein:
[0051] FIG. 1 comprises FIGS. 1A and 1B , and represents two schematic illustrations of an exemplary hand operated (or electrically rotating) instrument having a long, tapered shank which includes superficial horizontally striated grooves with slightly cutting edges that are separated by smooth areas ( FIG. 1A ), and which includes deep horizontally striated grooves with cutting edges that are separated by restricted smooth areas ( FIG. 1B ), according to preferred embodiments of the present invention;
[0052] FIG. 2 comprises FIGS. 2A and 2B , and represents two schematic illustrations of an exemplary hand operated (or electrically rotating) instrument having a long, tapered shank which includes superficial vertically striated grooves with slightly cutting edges that are separated by smooth areas ( FIG. 2A ), and which includes deep vertically striated grooves with cutting edges that are separated by restricted smooth areas ( FIG. 2B ), according to preferred embodiments of the present invention;
[0053] FIG. 3 comprises FIGS. 3A and 3B , and represents two schematic illustrations of an exemplary hand operated (or electrically rotating) instrument having a long, tapered shank which includes continuous, superficial transversally striated grooves with slightly cutting edges that are separated by smooth areas ( FIG. 3A ), and which includes deep transversally striated grooves with cutting edges that are separated by restricted smooth areas ( FIG. 3B ), according to preferred embodiments of the present invention;
[0054] FIG. 4 is a schematic illustration of an exemplary hand operated (or electrically rotating) instrument having a long, tapered shank with a beveled tip, and discontinuous, superficial transversally striated grooves with slightly cutting edges, separated by smooth areas, according to a preferred embodiment of the present invention;
[0055] FIG. 5 is a schematic illustration of an exemplary hand operated (or electrically rotating) instrument having a long, tapered shank with superficial transversally striated grooves with slightly cutting edges, separated by roughened areas (such as by sandblasting), according to a preferred embodiment of the present invention;
[0056] FIG. 6 is a schematic illustration of an exemplary hand operated instrument having a long, tapered shank with deep transversally striated grooves with cutting edges, separated by restricted smooth areas, according to a preferred embodiment of the present invention;
[0057] FIG. 7 is a schematic illustration of an exemplary electrically rotating instrument having a long, tapered shank with deep transversally striated grooves with cutting edges, separated by restricted smooth areas, according to a preferred embodiment of the present invention;
[0058] FIG. 8 is a schematic illustration of an exemplary electrically rotating (or hand operated) instrument having a long, tapered shank with a series of saw teeth separated by restricted smooth areas, according to a preferred embodiment of the present invention;
[0059] FIG. 9 comprises FIGS. 9A and 9B , and represents two schematic illustrations of an exemplary hand operated ( FIG. 9B ) and electrically rotating ( FIG. 9A ) spiral instrument with an upper cylindro-conical part having a conical tip, wherein the cylindro-conically shaped area is roughened, for example, by transversally grooved striations with cutting edges separated by restricted smooth or sandblasted areas, according to preferred embodiments of the present invention;
[0060] FIG. 10 comprises FIGS. 10A and 10B , and represents two schematic illustrations of an exemplary hand operated ( FIG. 10B ) and electrically rotating ( FIG. 10A ) instrument having a conical tip and a long, generally tapered shank that defines a series of cylindro-conically shaped areas (or sections) separated by spirally shaped sections, wherein the cylindro-conically shaped areas (or sections) are roughened by, for example, transversally grooved striations with cutting edges separated by restricted smooth areas, according to preferred embodiments of the present invention;
[0061] FIG. 11 comprises FIGS. 11A and 11B , and represents two schematic illustrations of an exemplary hand operated ( FIG. 11B ) and electrically rotating instrument ( FIG. 11A ) having a long, generally tapered shank that defines a series of spirally shaped sections separated by cylindro-conically shaped areas (or sections) that are roughened by, for example, transversally grooved striations with cutting edges separated by restricted smooth areas, according to preferred embodiments of the present invention;
[0062] FIG. 12 comprises FIGS. 12A and 12B , and represents two schematic illustrations of an exemplary hand operated ( FIG. 12B ) and electrically rotating ( FIG. 12A ) instrument having a conical tip and a long, generally tapered sand blasted shank that defines a series of cylindro-conically shaped areas (or sections) separated by spirally shaped sections, wherein the cylindro-conically shaped areas (or sections) are roughened by, for example, transversally grooved striations with cutting edges separated by restricted sand blasted areas, according to preferred embodiments of the present invention;
[0063] FIG. 13 comprises FIGS. 13A, 13B, 13C, and 13D , and illustrates a cross-sectional view of an exemplary tooth, with the cross-hatching removed for clarity of illustration, showing the sequential steps of progressively treating a root canal without a resistive path, obstruction, or blockage, using the instrument and process of the present invention;
[0064] FIG. 14 comprises FIGS. 14A, 14B, 14C, 14D, 14E, and 14F , and illustrates a cross-sectional view of an exemplary tooth, with the cross-hatching removed for clarity of illustration, showing the sequential steps of progressively treating a root canal that is blocked by a fragment of a broken instrument, such as a file, by bypassing the lodged fragment using the instrument and process of the present invention;
[0065] FIG. 15 comprises FIGS. 15A, 15B, and 15C and illustrates a cross-sectional view of an exemplary tooth, with the cross-hatching removed for clarity of illustration, showing the sequential steps of progressively treating a root canal that is blocked by hypercalcification, by piercing the hypercalcification using the instrument and process of the present invention;
[0066] FIG. 16 comprises FIGS. 16A, 16B, and 16C and illustrates a cross-sectional view of an exemplary tooth, with the cross-hatching removed for clarity of illustration, showing the sequential steps of progressively treating a root canal that is partially blocked by a shoulder, by bypassing the shoulder using the instrument and process of the present invention;
[0067] FIG. 17 comprises FIGS. 17A, 17B, and 17C and illustrates a cross-sectional view of an exemplary tooth, with the cross-hatching removed for clarity of illustration, showing the sequential steps of progressively treating a root canal that is blocked by a residual resistant paste, by piercing and removing the resistant paste using the instrument and process of the present invention;
[0068] FIG. 18 is a flow chart that illustrates the endodontic treatment process that does not exhibit signs of a resistive path, obstruction, or blockage, by selectively using the instruments of FIGS. 1B, 2B, 3B, and 6 through 8 according to the present invention;
[0069] FIGS. 19A and 19B represent a flow chart that illustrates the endodontic treatment method of bypassing root obstructions resulting from fractured instruments, by selectively using the instruments of FIGS. 1A, 1B, 2A, 2B, 3A, 3B , and 4 through 8 according to the present invention;
[0070] FIGS. 20A and 20B represent a flow chart that illustrates the endodontic treatment method of penetrating root obstructions resulting from hypercalcification, by selectively using the instruments of FIGS. 1A, 1B, 2A, 2B, 3A, 3B, and 5 through 8 according to the present invention;
[0071] FIGS. 21A and 21B represent a flow chart that illustrates the endodontic treatment method of bypassing root obstructions resulting from a shoulder obstruction, by selectively using the instruments of FIGS. 1A, 1B, 2A, 2B, 3A, 3B , and 5 through 8 according to the present invention;
[0072] FIGS. 22A and 22B represent a flow chart that illustrates the endodontic treatment method of penetrating root obstructions resulting from a previous root canal treatment, by selectively using the instruments of FIGS. 1A, 1B, 2A, 2B, 3A, 3B, and 4 through 8 according to the present invention; and
[0073] FIGS. 23A, 23B, 23C, 24A, 24B, 24C, 25A, 25B, 25C, 25D, 26A, 26B, 27A, 27B, 27C, 28A, 28B, 28C, 28D, 29A, 29B , 29 C, 30 A, 30 B, 31 A, 31 B, 32 A, 32 B, 32 C, 33 A, 33 B, 33 C, 33 D, 34 , 35 , 36 A, 36 B, 36 C, 37 A, 37 B, 38 A, and 38 B are X-ray views that illustrate various cases treated by the instruments and methods of the present invention.
[0074] It should be understood that the sizes of the different components in the figures might not be in exact proportion, and are shown for visual clarity and for the purpose of explanation.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0075] The instruments of the present invention can be used for probing, enlarging, penetrating, and bypassing difficult root canals obstructions, they may be hand operated or electrically operated, they may have a continued or a discontinued rotation, and they may have reciprocal rotation, a clockwise rotation, or an anti-clockwise rotation.
[0076] As it will be explained later in more specific details, each of these instruments comprises a handle that secures an elongated tapered shank. The cross section of the shank is generally circular, so as to eliminate sharp edges (or corners) that might otherwise attack the dental wall and strike the dentine wall at an acute angle, thus ultimately extending the life of the instrument.
[0077] The shank can assume a variety of designs, based on a combination of characteristics, including but not limited to: a roughed surface, a cutting surface, a smooth area, a conical cutting tip, a non-cutting tip, a beveled tip, and a non-beveled tip.
[0078] Based upon the various designs of their shanks, the endodontic instruments may be categorized as follows:
1 st Category: Instruments for catheterization and for passing through root obstacles. 2 nd Category: Instruments for fine and curved roots. 3 rd Category: Instruments that may be used for enlarging and shaping root canals.
[0082] Each of these categories will now be described in more detail.
[0083] 1st Category: Instruments for Catheterization and for Passing Through Root Obstacles, Shoulders, Resistant Paste, and Hypercalcifications
[0084] This category comprises two classes of instruments:
[0085] First (1 st ) Class: Instruments for Passing Through Root Obstacles, Shoulders, Resistant Paste, and Hypercalcifications
[0086] This class includes hand operated and electrically rotating instruments having a number of superficial horizontally, vertically, or transversally striated grooves (also referred to as “shallow grooves”) that define slightly cutting edges, and that are either separated by smooth areas or sandblasted areas or even instruments that are completely sandblasted. As used herein, the term “shallow” denotes a general depth that ranges between approximately 0.06 mm and 0.4 mm. The instruments in this class include a generally circular cross-section, and a conical tip that may be cutting or non-cutting, beveled or non-beveled.
[0087] The shanks of the hand operated instruments may be made from stainless steel, and range from No. 10 to 25. The shanks of the hand operated instruments that are made from NiTi, preferably range from No. 20 to 25. The shafts of the electrically rotating NiTi instruments preferably range from No. 10 to 25. The shafts of all these instruments have a taper ranging from approximately 0% to 4%, and a length that ranges from approximately 12 mm to 32 mm. ( FIGS. 1-5 ).
[0088] The more preferred embodiments of the instruments in this class that provide optimal results are the hand operated instruments Nos. 10, 15, and 20, with a shank taper with an approximate 2% taper, and that are made from stainless steel. Other preferred embodiments include the hand operated instruments No. 20 with an approximate 4% shank taper that is made from NiTi. Additional preferred embodiments include the electrically rotating instruments that are made from NiTi, Nos. 10, 15, and 20, with a shank taper of approximately 2%, and Nos. 20 and 25 with a shank taper of approximately 4%.
[0089] Sandblasted instruments with superficial grooves with slightly cutting edges, have provided good penetration results, namely in engraving a cutting adjacent to the fractured instrument without encroaching with the coils of the fractured instrument, and in removing the dentine of the root canal. Optimal penetration results have been obtained with instruments that are sandblasted with aluminum oxide.
[0090] Second (2 nd ) Class: Instruments for Catheterization
[0091] This class includes hand operated instruments having a series of horizontally, vertically, or transversally striated deep grooves with cutting edges, that are separated by restricted smooth or sandblasted areas or even instruments that are completely sandblasted. As used herein, the term “deep” denotes a general depth that ranges between approximately between 0.12 mm and 0.8 mm. The instruments in this class include a generally circular cross section, and a conical tip that may be cutting or non-cutting.
[0092] The shanks of these instruments range from No. 6 to 20. The shanks may be made from stainless steel, and range from No. 6 to 20. The shanks may alternatively be made from NiTi, and range from No. 20 to 40. The shafts of all these instruments have a taper of approximately 0%, 1%, 2%, and 4%, and a length that ranges from approximately 12 mm to 32 mm ( FIG. 6 ). The preferred embodiments of the instruments in this class that provide optimal results are those made of stainless steel with Nos. 10, 15, and 20, with an approximate 2% taper. These preferred embodiments include instruments that are made from NiTi, No. 20, with an approximate 4% shank taper.
[0093] The instruments of this 1 st category will now be described with reference to FIGS. 1 through 6 . FIG. 1A is a schematic illustration of an exemplary hand operated instrument (or file) 100 for use as a first category, first class instrument, according to a preferred embodiment of the present invention. The instrument 100 generally includes an elongated, tapered shank 105 with superficial horizontally striated grooves 110 with slightly cutting edges that are separated by smooth areas 111 .
[0094] In one exemplary embodiment, the grooves 110 form horizontal linear striations that are approximately 1 mm wide. It should be understood that the grooves 110 might assume other different patterns. The width of each smooth area 111 varies between approximately 2 mm and 3 mm.
[0095] The instrument 100 further includes a tip 120 and a handle 125 . The tip 120 may be cutting or non-cutting, beveled or non beveled, depending on the desired application. The handle 125 secures one end of the shank 105 , and enables an endodontist to safely and ergonomically hold the instrument 100 while performing the treatment. It should be understood that the instrument 100 may alternatively be electrically rotating, in which case, the handle 125 is replaced with an appropriate handle or interface that connects the shank 105 to an external rotary source (not shown), as is known or available in the field.
[0096] The shank 105 can be made of any suitable material, including but not limited to stainless steel or NiTi (Nickel Titanium). The shank 105 may have a constant or variable taper along its axial length, ranging from approximately 0% to 4%, a length ranging from approximately 12 mm to 32 mm, and a width ranging from approximately No. 10 to 25.
[0097] FIG. 1B illustrates another instrument 150 for use as a first category, second class instrument according to a preferred embodiment of the present invention. The instrument 150 may also be used as a second or third category instrument, as explained herein.
[0098] The instrument 150 is generally similar in design and construction to the instrument 100 of FIG. 1A , and comprises an elongated, tapered shank 155 with deep horizontally striated grooves 160 with cutting edges that are separated by restricted smooth areas 161 . In one exemplary embodiment, the grooves 160 form horizontal linear striations that are approximately 2 to 3 mm wide. It should be understood that the grooves 160 might assume other patterns. The width of each smooth area 161 is approximately 1 mm.
[0099] The instrument 150 further includes a cutting or non-cutting tip 120 and a handle 125 , whose design and function are explained earlier in connection with the instrument 100 .
[0100] It should be understood that these instruments 100 , 150 can be modified, as explained herein, for use as electrically rotating instruments.
[0101] FIG. 2 respectively illustrates two exemplary hand operated instruments 200 ( FIG. 2A ) and 250 ( FIG. 2B ) that are generally similar in design and construction to the instruments 100 , 150 (respectively) of FIG. 1 . It should be understood that these instruments 200 , 250 can be modified, as explained herein, for use as electrically rotating instruments.
[0102] The instrument 200 can be used as a first category, first class instrument. It includes an elongated, tapered shank 205 with superficial vertically striated grooves 210 with slightly cutting edges that are separated by smooth areas 211 , according to a preferred embodiment of the present invention. In one exemplary embodiment, the grooves 210 form vertical linear striations that are approximately 1 mm in width. The smooth areas 211 separate the grooves 210 at a distance of approximately 2 to 3 mm.
[0103] The instrument 200 further includes a cutting or non-cutting tip 220 and a handle 125 , which are respectively similar to the tip 120 and handle 125 of the instrument 100 of FIG. 1A .
[0104] The instrument 250 of FIG. 2B can be used as a first category, second class instrument, according to a preferred embodiment of the present invention. It may also be used as a second or third category instrument, as explained herein. The instrument 250 includes an elongated, tapered shank 255 having deep vertically striated grooves 260 with cutting edges that are separated by restricted smooth areas 261 . In one exemplary embodiment, the grooves 260 form vertical linear striations that are approximately 2 to 3 mm in width. The smooth areas 261 separate the grooves 260 at a distance of approximately 1 mm.
[0105] The instrument 250 further includes a cutting or non-cutting tip 220 and a handle 125 , which are respectively similar to the tip 120 and handle 125 of the instrument 150 of FIG. 1B .
[0106] FIG. 3 respectively illustrates two exemplary hand operated instruments 300 ( FIG. 3A ) and 350 ( FIG. 3B ) that are generally, respectively similar in design and construction to the instruments 100 , 150 of FIG. 1 and 200, 250 of FIG. 2 . It should be understood that these instruments 300 , 350 can be modified, as explained herein, for use as electrically rotating instruments.
[0107] The instrument 300 can be used as a first category, first class instrument. It includes an elongated, tapered shank 305 with superficial transversally striated grooves 310 with slightly cutting edges that are separated by smooth areas 311 , according to a preferred embodiment of the present invention. In one exemplary embodiment, the grooves 310 form transversally linear striations that are approximately 1 mm in width. The smooth areas 311 separate the grooves 310 at a distance of approximately 2 mm to 3 mm.
[0108] The instrument 300 further includes a cutting or non-cutting tip 320 and a handle 125 , which are respectively similar to the tip 120 and handle 125 of the instrument 100 of FIG. 1A .
[0109] The instrument 350 of FIG. 3B can also be used as a first category, second class hand operated instrument, according to a preferred embodiment of the present invention. It may also be used as a second or third category instrument, as explained herein. The instrument 350 includes an elongated, tapered shank 355 with deep transversally striated grooves 360 with cutting edges that are separated by restricted smooth areas 361 . In one exemplary embodiment, the grooves 360 form transversally linear striations that are approximately 2 to 3 mm in width. The smooth areas 361 separate the grooves 360 at a distance of approximately 1 mm.
[0110] The instrument 350 further includes a cutting or non-cutting tip 320 and a handle 125 , which are respectively similar to the tip 120 and handle 125 of the instrument 150 of FIG. 1B .
[0111] FIG. 4 illustrates an exemplary hand operated instrument 400 that is generally similar in design and construction to the instrument 300 of FIG. 3A . It should be understood that the instrument 400 can be modified, as explained herein, for use as an electrically rotating instrument.
[0112] The instrument 400 can be used as a first category, first class instrument. It includes an elongated, tapered shank 405 with superficial transversally striated grooves 410 with slightly cutting edges that are separated by smooth areas 411 , according to a preferred embodiment of the present invention. In one exemplary embodiment, the grooves 410 form short, transversally linear striations that are approximately 1 mm in width. The distance between two consecutive grooves 410 may be adjusted so that it can be either fixed or variable, along the axial length of the shank 405 . As an example only, the separation of the grooves 410 (which constitutes the width of the smooth areas 411 ) can vary between approximately 2 mm and 3 mm.
[0113] The instrument 400 further includes a pointed, beveled cutting tip 420 and a handle 125 .
[0114] FIG. 5 illustrates an exemplary hand operated instrument 500 that is generally similar in design and construction to the instrument 300 of FIG. 3A . It should be understood that the instrument 500 can be modified, as explained herein, for use as an electrically rotating instrument.
[0115] The instrument 500 can be used as a first category, first class instrument. It includes an elongated, tapered shank 505 with superficial transversally striated grooves 510 with slightly cutting edges that are separated by roughened areas 511 , according to a preferred embodiment of the present invention. In one exemplary embodiment, the grooves 510 form short, transversally linear striations.
[0116] In a most preferred embodiment, the roughened areas 511 are formed by sandblasting. The instrument 500 further includes a cutting or non-cutting tip 520 and a handle 125 .
[0117] FIG. 6 illustrates an exemplary hand operated instrument 600 that is generally similar in design and construction to the instrument 350 of FIG. 3B . It should be understood that the instrument 600 can be modified, as explained herein, for use as an electrically rotating instrument.
[0118] The instrument 600 can be used as a first category, second class instrument. It includes an elongated, tapered shank 605 with deep transversally striated grooves 610 with cutting edges that are separated by restricted smooth areas 611 , according to a preferred embodiment of the present invention. In one exemplary embodiment, the grooves 610 form short, transversally linear striations that are approximately 2 to 3 mm in width. The separation distance between the grooves 610 may be adjusted so that it can be either fixed or variable, along the axial length of the shank 605 . As an example only, the separation of the grooves 610 (which constitutes the width of the smooth areas 611 ) is 1 mm.
[0119] The instrument 600 further includes a pointed, cutting or non-cutting tip 620 and a handle 125 .
[0120] 2 nd Category: Instruments for Penetrating Fine and Curved Root Canals
[0121] As illustrated in FIG. 7 , this category comprises electrically operated rotating instruments (e.g., 700 ) that are preferably (but not exclusively) made for example of NiTi, from No. 10 to 20, with a shank 705 having a taper of approximately 2%. Although the illustrated instrument 700 is shown to include a series of transversal, deep, striated grooves 710 with cutting edges, it should be understood that other embodiments can alternatively include a series of horizontally or vertically striated, deep grooves with cutting edges, that are separated by either smooth or roughened (i.e., sandblasted) restricted areas 711 , or even instruments that are completely sandblasted.
[0122] The shank 705 of the instrument 700 has a generally circular cross-section, and a conical cutting or non-cutting tip 720 , with a length ranging from approximately 21 to 32 mm. The circular cross section and conical tip 720 of the shank 705 helps create a space around the segment(s) of the fractured instruments that are lodged within the root canal, thus enabling the instruments of the 1 st category, 1 st class, to bypass the lodged fractured segment(s).
[0123] A handle 725 secures the shank 705 to an external motorized source (not shown).
[0124] 3 rd Category: Instruments which May be Used for Enlarging and Shaping Root Canals
[0125] As illustrated in FIG. 8 , this category comprises electrically operated rotating instruments (e.g., 800 ) made of NiTi from No. 20 to 40, with a shank 805 having a generally circular cross section. Although the illustrated instrument 800 is shown to include a conical cutting or non-cutting tip 820 , with a series of saw teeth 810 that are separated by restricted smooth areas 811 , it should be understood that other embodiments can further include horizontally, vertically, or transversally striated grooves.
[0126] The saw teeth configuration expels the dental debris from the root canal and lessens the rubbing force of the instrument on the walls of the root canal, especially when using files from Nos. 20 to 40, thus avoiding root canal cracks.
[0127] The taper of the shank 805 ranges from approximately 4% to 10%, and has a length of approximately 21 mm to 32 mm.
[0128] It is important to note that the shanks of the instruments in all the foregoing three categories may or may not be sandblasted. It is also noteworthy to indicate that the instruments of the above three categories successfully penetrate root hypercalcifications that are formed in the root canal. In addition, a file instrument No. 20 with a 4% taper, and a file instrument No. 17 with a 4% taper, have shown remarkable utility in creating a space around fractured, lodged fragments of previously used instruments, so that the instruments of the 1 st category, 1 st class, may be used in order to bypass these fractured instruments.
[0129] Alternative embodiments that are contemplated by the present invention include but are not limited to the following hand operated and electrically operated instruments:
[0130] FIGS. 9A, 9B illustrate an electrically operated instrument 900 and a manually operated instrument 950 that is generally similar in design and function to the electrically operated instrument 900 , and therefore only one instrument will be described in detail. The electrically operated instrument 900 generally includes an elongated, tapered shank 905 that defines an upper cylindro-conical section 910 and a spirally (or helically) shaped lower section 915 .
[0131] The cylindro-conical section 910 includes at its upper end, a tip 920 that may be cutting or non-cutting, depending on the desired application. While in this particular illustration the cylindro-conical section 910 is illustrated as being a roughened surface, it should be understood that the cylindro-conical section 910 could include striated grooves with cutting edges separated by smooth or sandblasted areas. The length of the shank 905 preferably ranges between approximately 12 mm and 32 mm, and its width preferably varies from No. 10 to 40. The taper of the instrument preferably ranges from approximately 2% to 10%. In a preferred embodiment, the entire shank 905 of the instrument 900 is sandblasted.
[0132] Section 910 is intended to penetrate root canal blockages while section 915 serves to debride and to shape the opened path.
[0133] The instrument 900 further includes a handle 925 that secures one end of the shank 905 , and that enables an endodontist to connect the instrument 900 to an external rotary source (not shown) as is known or available in the field. Similarly, the instrument 950 further includes a manual handle 955 that secures one end of the shank 905 , and that enables an endodontist to safely and ergonomically hold the instrument 950 while manually performing the treatment.
[0134] FIGS. 10A, 10B illustrate an electrically operated instrument 1000 , and a manually operated instrument 1050 that is generally similar in design and function to the electrically operated instrument 1000 , and therefore only one instrument will be described in detail. The electrically operated instrument 1000 generally includes an elongated, tapered shank 1005 that defines a plurality of roughened cylindro-conical sections 1010 , 1011 , 1012 , that are separated by a plurality of spirally (or helically) shaped sections 1015 , 1016 .
[0135] The cylindro-conical section 1010 of the instrument 1000 comprise striated grooves with cutting edges separated by smooth or sandblasted areas and further includes at its forwardmost end, a tip 1020 that may be cutting or non-cutting, depending on the desired application. The length of the shank 1005 ranges from approximately 12 mm to 32 mm, and its width preferably varies from No. 10 to 40. The taper of the instrument preferably ranges from approximately 2% to 10%. In a preferred embodiment, the whole instrument will be sandblasted.
[0136] Section 1010 is intended to penetrate root canal blockages while section 1015 serves to debride and to shape the opened path.
[0137] The instruments illustrated in FIG. 10 provide better penetration results than the instruments in FIG. 9 . They are preferred in case of hard hypercalcifications and resistant paste.
[0138] FIGS. 11A, 11B respectively illustrate an electrically operated instrument 1100 , and a manually operated instrument 1150 that is generally similar in design and function to the electrically operated instrument 1100 , and therefore only one instrument will be described in detail. The electrically operated instrument 1100 generally includes an elongated, tapered shank 1105 that defines a plurality of roughened cylindro-conical sections 1110 , 1111 , which are separated by a plurality of spirally (or helically) shaped sections 1115 , 1116 , 1117 .
[0139] The spiral section 1115 of the instrument 1100 further includes at its forwardmost end, a tip 1120 that may be cutting or non-cutting, depending on the desired application. The length of the shank 1105 ranges from approximately 12 mm to 32 mm, and its width preferably varies from No. 10 to 40. The taper of the instrument preferably ranges from approximately 2% to 10%.
[0140] In the exemplary embodiment of FIG. 11 , the cylindro-conical sections 1110 , 1111 may be striated with groves with cutting edges separated by smooth or sandblasted areas. In a preferred embodiment, the whole instrument will be sandblasted.
[0141] FIGS. 12A, 12B illustrate yet other alternative embodiments of an electrically operated instrument 1200 and a manually operated instrument 1250 , that are respectively, generally similar in design and function to the instruments 1000 , 1050 of FIGS. 10A, 10B .
[0142] The electrically operated instrument 1200 generally includes an elongated, tapered shank 1205 that defines a plurality of roughened cylindro-conical sections 1210 , 1211 , 1212 , that are separated by a plurality of spirally (or helically) shaped sections 1215 , 1216 . The cylindro-conical section 1210 of the instrument 1200 further includes at its forwardmost end, a tip 1220 that may be cutting or non-cutting, depending on the desired application. The length of the shank 1205 ranges from approximately 12 mm to 32 mm, and its width preferably varies from No. 10 to 40. The taper of the instrument preferably ranges from approximately 2% to 10%.
[0143] In the exemplary embodiment of FIG. 12 , the cylindro-conical sections 1210 , 1211 , 1212 may be striated with groves with cutting edges separated by smooth or sandblasted areas while the spiral sections may be similarly sandblasted.
[0144] Having described the exemplary instruments embodied by the present invention, the methods of using these instruments will now be described in more detail, in connection with the drawings, particularly FIGS. 13 through 18 .
[0145] Methods of Using the Instruments in Treating Root Canals
[0146] The new root canal treatment method generally aims to bypass root obstructions resulting from fractured instruments and to penetrate hypercalcification, to bypass dental shoulders, to penetrate resistant paste, curved root canals and other obstructions resulting from a previous root treatment. More specifically, the following exemplary treatment methods will now be described in more detail:
[0000] I—Method of treating a root canal that does not exhibit signs of a resistive path, obstruction, or blockage.
II—Method of bypassing root obstructions resulting from fractured instruments.
III—Method of penetrating root obstructions resulting from hypercalcification.
IV—Method of penetrating root obstructions resulting from curved root canals.
V—Method of bypassing root obstructions resulting from a shoulder.
VI—Method of penetrating root obstructions resulting from a previous root canal treatment.
[0147] I—Method of Treating a Root Canal that does not Exhibit Signs of a Resistive Path, Obstruction, or Blockage
[0148] FIG. 13 comprises FIGS. 13A, 13B, 13C, and 13D and illustrates an exemplary tooth 1300 that does not exhibit signs of a resistive path, obstruction, or blockage. With further reference to FIG. 18 , an endodontic treatment method 1800 is performed according to the following steps:
[0149] As illustrated in FIG. 13A , the endodontist starts at step 1810 of FIG. 18 , to enlarge the root canal 1312 by selectively and sequentially using the instruments (denoted with numeral reference 1320 ) of the 1 st category, 2 nd class (e.g., FIGS. 1B, 2B, 3B and 6 ), starting for example with a manual instrument No. 8 having an approximate 2% taper, in increasing order to No. 15 with an approximate 2% taper (1 st category, 2 nd class), exerting a manual force with a clockwise 90-degree rotation along the arrow F, in order to reach the apex 1333 of the root canal 1312 .
[0150] As illustrated at step 1820 of FIG. 18 , the endodontist further enlarges the root canal 1312 using for example, an electrically rotating instrument (denoted with numeral reference 1330 ) selected from the 2 nd category (e.g., FIG. 7 ), starting with No. 10 having an approximate 2% taper, in an increasing order to No. 20, along the arrow F in order to reach the apex of the root canal 1333 .
[0151] As illustrated at step 1830 of FIG. 18 and in FIG. 13B , the endodontist continues to enlarge the root canal 1312 using for example, an electrically rotating instrument 1320 , which is selected from the 3rd category (e.g., FIG. 8 ), starting with an instrument from No. 20 to No. 25 with an approximate 4% taper to No. 25 with an approximate 6% taper whenever possible, in order to reach the apex 1333 of the root canal 1312 . In a preferred embodiment, an instrument with No. 20 having an approximate 4% taper can be used.
[0152] As illustrated at step 1840 and also in FIG. 13C , upon completion of step 1830 as described earlier, the endodontist clears the widened root canal 1312 of any debris, as is known in the field, in preparation for the final obturation step.
[0153] As illustrated at step 1850 and also in FIG. 13D , the endodontist obturates the root canal 1312 with the appropriate filling material 1350 , as is known in the field.
[0154] II—Method of Bypassing Root Obstructions Resulting from Fractured Instruments
[0155] With reference to FIG. 14 , it comprises FIGS. 14A, 14B, 14C, 14D, 14E , and 14 F, and illustrates an exemplary tooth 1400 having a root canal 1412 within which an obstruction, such as a fragment 1410 of a fractured instrument (such as a file) is lodged by a previous root canal treatment. With further reference to FIGS. 19A and 19B , the treatment method 1900 is performed according to the following steps:
[0156] As further illustrated in FIG. 14A , at step 1910 of FIG. 19A , the endodontist enlarges the root canal 1412 by selectively and sequentially using the instruments (denoted with numeral reference 1420 ) of the 1 st category, 2 nd class (e.g., FIGS. 1B, 2B, 3B and 6 ), starting for example with a manual instrument No. 8 having an approximate 2% taper, in increasing order to No. 15 with an approximate 2% taper (1 st category, 2 nd class), exerting a manual force with a clockwise 90 degrees rotation in along the arrow F, in order to reach the fractured instrument 1410 of the root canal 1412 .
[0157] As illustrated at step 1920 of FIG. 19A and also in FIG. 14B , the endodontist further enlarges the root canal 1412 using for example, an electrically rotating instrument (denoted with numeral reference 1430 ) selected from the 2 nd category (e.g., FIG. 7 ), starting with No. 10 having an approximate 2% taper, in an increasing order to No. 20, in order to reach the fractured instrument in the root canal 1412 .
[0158] As illustrated at step 1930 of FIG. 19A and also in FIG. 14B , the endodontist continues to enlarge the root canal 1412 using for example, an electrically rotating instrument (denoted with numeral reference 1430 ) selected from the 3 rd category (e.g., FIG. 8 ), starting with an instrument from No. 20 to No. 25 with an approximate 4% taper to No. 25 with an approximate 6% taper whenever possible. In a preferred embodiment, an instrument with No. 20 having an approximate 4% taper can be used to reach the fractured instrument in the root canal 1412 .
[0159] For relatively simple cases, each new instrument (whether manual or electrically operated) is capable of bypassing the obstruction after enlarging the root canal 1412 according to above steps 1910 , 1920 , and 1930 .
[0160] However, for more complex cases, and as illustrated by step 1940 of FIG. 19A and FIG. 14C , the endodontist resumes process 1900 by engraving a cutting 1444 beside the obstruction 1410 , using new manual instruments, selected for example from the 1 st category, 1 st class, and preferably made of NiTi, No. 20, with an approximate 4% taper and a cutting tip (e.g., 120 , 220 , 320 , 520 or eventually 420 ). The endodontist starts by exerting a manual force with a clockwise 90-degree rotation, and then withdraws the instrument by exerting an anti-clockwise rotation of the same angle, along the rotational arrow M. The relatively large cross sectional surface of the cutting tip 120 , 220 , 320 , 520 or eventually 420 avoids opening a false canal when exerting a relatively high manual force.
[0161] The endodontist then enlarges the cutting 1444 into an initial path using a manual instrument (also denoted by the numeral reference 1440 ) selected for example from the 1 st category, 1 st class, and preferably made of NiTi, No. 20 with an approximate 4% taper and a non-cutting tip (e.g. 1633 B), exerting a manual force with a clockwise 90 degrees rotation along the arrow F, in order to preserve the initial path 1444 .
[0162] As further illustrated in FIG. 14D , and in order to further penetrate the obstructed canal through the opened initial path 1444 , the endodontist uses, at step 1960 of FIG. 19B , a manual instrument 1450 selected for example from the 1 st category, 1 st class, and preferably made of stainless steel, No. 20, having an approximate 2% taper with a cutting tip (e.g., 1633 A), for engraving a new cutting 1445 , adjacent to the obstruction 1410 , exerting a manual force with a clockwise 90-degree rotation along the arrow F.
[0163] Thereafter, the endodontist preferably uses, at step 1970 of FIG. 19B , to manually enlarge the newly opened cutting 1445 using an instrument (still denoted by 1450 ) selected for example from the 1 st category, 1 st class, and preferably made of stainless steel, No. 20, having an approximate 2% taper with a non-cutting tip (e.g., 1633 B).
[0164] The endodontist continues to enlarge the new path 1445 using a manual instrument (still denoted by 1450 ) selected for example from the 1 st category, 1 st class, and preferably made of NiTi, No. 20, having an approximate 4% taper with a cutting tip (e.g., 1633 A), followed by No. 20 having an approximate 4% taper with a non-cutting tip (e.g., 1633 B), in order to preserve the new path 1445 .
[0165] In case the endodontist encounters difficulty in penetrating the root canal 1412 , and whenever suitable, the endodontist may use a manual instrument 1440 ( FIG. 14C ) selected for example from the 1 st category, 1 st class, and preferably made of stainless steel, No. 20, having an approximate 2% taper with a cutting tip (e.g., 1633 A), followed by No. 20 having an approximate 2% taper with a non-cutting tip (e.g., 1633 B).
[0166] Alternatively, the endodontist may use a manual instrument 1450 ( FIG. 14D ) selected for example from the 1 st category, 1 st class, and preferably made of stainless steel, No. 15, having an approximate 2% taper with a cutting tip (e.g., 1633 A) in order to create a new cutting. This step is then followed by the use of a manual instrument selected for example from the 1 st category, 1 st class, and preferably made of stainless steel, No. 15, having an approximately 2% taper with a non-cutting tip (e.g., 1633 B), in order to preserve the newly opened path 1445 .
[0167] In the event the instruments that are collectively referenced by 1450 fail to open or enlarge the required path 1445 , the endodontist uses a smaller instrument preferably made of stainless steel, in the same sequence as described above, until the apex 1466 of the root canal 1412 is reached (step 1980 ), as follows: The path 1445 is enlarged manually, at step 1970 , using sequentially hand operated stainless steel instruments with cutting and non-cutting tips from No. 8 or 10 until No. 20 of approximately 2% taper (1 st category 1 st class). The introduction of the instrument with a cutting tip is followed by the use of the same instrument with a non-cutting tip. Alternatively, use may be made of NiTi instrument 1450 , No. 20 with an approximate 4% taper (1 st category, 1 st class), first with instrument 1450 having a cutting tip (e.g., 1633 A), then with instrument 1450 having a non-cutting tip (e.g., 1633 B).
[0168] The endodontist starts at step 1980 with electrically operated instruments of the 1 st category, 1 st class, which are preferably made of NiTi, and having a non-cutting tip (e.g., 1633 B), in an increasing order starting by using instrument no. 10 with approximately 2% taper until reaching No. 20 of approximately 2% taper.
[0169] Then, the endodontist continues with electrically operated instruments of the 2 nd category, which are preferably made of NiTi, and having a non-cutting tip (e.g., 1633 B), in an increasing order instruments from No. 20 to No. 25 having approximately 2% taper.
[0170] Finally, the endodontist completes the enlargement of the path 1445 with electrically operated instruments of the 3 rd category, which are preferably made of NiTi, and having a non-cutting tip (e.g., 1633 B), namely instrument No. 20 or 25 having approximately 4% taper.
[0171] It should be noted that the use of files (or instruments) having a beveled tip is recommended only in case the aforesaid instruments fail to engrave a cutting or path adjacent to the fractured instrument 1410 , particularly in case of difficult hypercalcification cases or in the case the cross section of the fractured instrument 1410 is relatively large.
[0172] As illustrated at step 1990 and also in FIG. 14E , upon completion of step 1980 as described earlier, the endodontist clears the widened root canal 1445 of any debris, as is known in the field, in preparation for the final obturation step.
[0173] As illustrated at step 1999 and also in FIG. 14F , the endodontist obturates the root canal 1445 with the appropriate filling material 1446 , as is known in the field. It should be noted that the obturation may be performed with or without removing the fragment 1410 of the fractured instrument.
[0174] Although the conventional art describes that the use of electrically operated files may not be proper in case of treating dental roots with fractured instruments 1410 , the present invention teaches that it is possible to directly reach the apex 1466 , at step 1999 , by using electrically operated instruments with non-cutting tips, made of NiTi, after step 1970 , in an increasing order from No. 10 with an approximate 2% taper (selected from the 1 st category, 1 st class) to No. 20 with an approximate 4% taper (selected from the 1 st category, 1 st class), followed by the sequential use of instruments selected from the 2 nd and 3 rd categories, as deemed appropriate by the endodontist.
[0175] Alternatively, the present invention teaches that in less difficult cases, it is possible from step 1950 to directly reach the apex 1466 , step 1999 , by using electrically operated instruments with non-cutting tips, made of NiTi, starting by enlarging the initial path 1444 with No. 20 having an approximate 4% taper (1 st category, 1 st class); then using in an increasing order NiTi instruments with non-cutting tip from No. 10 with an approximate 2% taper (selected from the 1 st category, 1 st class) to No. 20 with an approximate 4% taper (selected from the 1 st category, 1 st class), followed sequentially by instruments selected from the 2 nd and 3 rd categories, as deemed appropriate by the endodontist.
[0176] It is worth noting that the root canal is irrigated with sodium hypochloride and EDTA (Ethylenediaminetetraacetic acid) at each relevant step of process 1900 .
[0177] The following X-Rays FIGS. 23A, 23B, 23C, 24A, 24B, 24C, 25A, 25B, 25C, 25D, 26A, 26B, 27A, 27B, 27C, 28A, 28B, 28C, 28D, 29A, 29B , 29 C, 30 A, 30 B, 31 A, 31 B, 32 A, 32 B, 32 C, 33 A, 33 B, 33 C, 33 D, 34 , 35 , 36 A, 36 B, 36 C, 37 A, 37 B, 38 A, and 38 B provide supporting illustrations of this novel process 1900 :
[0178] FIG. 23A shows a broken file in tooth no. 26 blocking the totality of the root canal. FIG. 23B shows the bypassing of the broken file and reaching the apex with the new instrument according to the present invention. FIG. 23C shows the fully hermetic obturation of the treated root canal.
[0179] FIG. 24A shows a broken file in tooth no. 46 blocking the totality of the root canal. FIG. 24B shows the bypassing of the broken file and the piercing of the hypercalcification and reaching the apex with the new instrument according to the present invention. FIG. 24C shows the fully hermetic obturation of the treated root canal.
[0180] FIG. 25A shows a hypercalcification, a shoulder, and a broken file in the mesial canals of tooth no. 36. FIG. 25B shows the broken file. FIG. 25C shows the bypassing of the broken file, the penetration of the shoulder and the piercing of the hypercalcification in the 2 nd mesial canal and reaching the apex with the new instrument, according to the present invention. FIG. 25D shows the fully hermetic obturation of the treated root canal.
[0181] FIG. 26A shows two fractured files in the mesio vestibular canal in tooth no. 46, blocking the totality of the root canal. FIG. 26B shows the bypassing of the two broken files and reaching the apex with the new instrument according to the present invention.
[0182] FIG. 27A shows three broken files in tooth no. 35 blocking the totality of the root canal. FIG. 27B shows the bypassing of the three broken files and reaching the apex with the new instrument according to the present invention. FIG. 27C shows the fully hermetic obturation of the root canal.
[0183] FIG. 28A shows a broken file in tooth no. 47 blocking the totality of the root canal due to hypercalcification. FIG. 28B shows a cutting made with the new instrument according to the invention, and a second broken file. FIG. 28C shows the bypassing of the two broken files and the piercing of the hypercalcification and reaching the apex with the new instrument according to the present invention. FIG. 28D shows the fully hermetic obturation of the treated root canal.
[0184] More specifically, and as a comparative illustration, instead of using the new instruments according to the invention, a conventional file was used to enlarge the cutting and to bypass the broken file. However, the conventional file was broken, as expected, while the new instrument according to the invention has successfully bypassed the two broken files, pierced the hypercalcification, and reached the apex, without making a false canal ( FIG. 28C ).
[0185] FIG. 29A shows two superposed broken files in tooth no. 26 blocking the third apical of the root canal. FIG. 29B shows the bypassing of the broken files and reaching the apex with the new instrument according to the present invention. FIG. 29C shows the fully hermetic obturation of the treated root canal.
[0186] FIG. 30A shows a broken file in tooth no. 37 blocking the third apical of the root canal. FIG. 30B shows the bypassing of the broken file and reaching the apex with the new instrument according to the present invention.
[0187] FIG. 31A shows a false canal and two broken files in tooth no. 36 blocking the apex of the root canal. FIG. 31B shows the avoidance of the false canal and the bypassing of the broken file and reaching the apex with the new instrument according to the present invention.
[0188] FIG. 32A shows a broken file in the third apical of the mesial canal tooth no. 46 blocking the apex. FIG. 32B shows the bypassing of the broken file and reaching the apex with the new instrument according to the present invention. FIG. 32C shows the fully hermetic obturation of the treated root canal.
[0189] III—Method of Penetrating Root Obstructions Resulting from Hypercalcification
[0190] With reference to FIG. 15 , it comprises FIGS. 15A, 15B, and 15C and illustrates an exemplary tooth 1500 having a root canal 1512 that is blocked or obstructed by hypercalcification 1510 . With further reference to FIGS. 20A, 20B , the treatment method 2000 is performed according to the following steps:
[0191] As further illustrated in FIG. 15A , the endodontist enlarges, at step 2010 of FIG. 20A , the root canal 1512 of the tooth 1500 by starting with a manual instrument selected from the 1 st category, 2 nd class, No. 8, with an approximate 2% taper, in an increasing order to an instrument selected from the 1 st category, 2 nd class, No. 15, with an approximate 2% taper, exerting a manual force with a clockwise 90-degree rotation along the arrow F, until the tip 1525 of the instrument 1520 reaches the hypercalcification 1510 .
[0192] The endodontist then further enlarges, at step 2020 , the root canal 1512 using electrically rotating instruments 1520 selected from the 2 nd category, starting with No. 10 with an approximate 2% taper, in an increasing order to No. 20 with an approximate 2% taper, until reaching the hypercalcification.
[0193] Still at step 2020 , the endodontist continues to enlarge the root canal 1512 using electrically rotating new instruments that are selected from the 3 rd category, using files from No. 20 to No. 25 with an approximate 4% taper, to No. 25 with an approximate 6% taper whenever possible. Preferred results were obtained with a No. 20 instrument with an approximate 4% taper, until reaching the hypercalcification 1510 .
[0194] The endodontist then starts piercing the hypercalcification 1510 at step 2030 , to form an initial path 1555 therewithin, using manual NiTi instruments 1530 selected from the 1 st category, 1 st class, No. 20 with an approximate 4% taper, and a cutting tip 1525 . The endodontist exerts a manual force with a clockwise 90-degree rotation. The endodontist then withdraws the instrument 1530 by exerting an anti-clockwise rotation of the same angle. The relatively large cross-sectional surface of the cutting tip 1525 avoids opening a false canal when exerting a relatively high manual force.
[0195] The endodontist continues at step 2040 by enlarging the initial path 1555 , using a manual NiTi instrument that is selected from the 1 st category, 1 st class, No. 20 having an approximate 4% taper with a non-cutting tip (e.g., 1633 B), in order to preserve the opened initial path 1555 .
[0196] The endodontist then continues to step 2050 , in order to enlarge the initial path 1555 and to pierce the remainder of the hypercalcification, by using a manual stainless steel instrument selected from the 1 st category, 1 st class, No. 20, with an approximate 2% taper and a cutting tip 1525 . It is recommended to continue to manually enlarge the initial path 1555 using a manual stainless steel instrument selected from the 1 st category, 1 st class, No. 20 with an approximate 2% taper and a non-cutting tip (e.g., 1633 B).
[0197] At step 2060 , the endodontist further enlarges the initial path 1555 by first using a manual NiTi instrument selected from the 1 st category, 1 st class, No. 20, with an approximate 4% taper and a cutting tip 1555 , and then using a manual NiTi instrument also selected from the 1 st category, 1 st class, No. 20, with an approximate 4% taper and a non-cutting tip (e.g., 1633 B), so as to preserve the initial path 1555 .
[0198] In the event the endodontist encounters difficulty in penetrating the root canal 1512 , manual stainless steel instrument 1540 selected from the 1 st category, 1 st class, No. 20, with an approximate 2% taper and a cutting tip 1525 is used whenever feasible. Otherwise, the endodontist uses a manual stainless steel instrument 1540 selected from the 1 st category, 1 st class, No. 15, with an approximate 2% taper and a cutting tip 1525 , in order to pierce a new path that is adjacent to the initial path 1555 . This step is followed by the use of a manual stainless steel instrument 1540 selected from the 1 st category, 1 st class, No. 15, with an approximate 2% taper and a non-cutting tip, in order to preserve the new adjacent path. In case the instruments 1540 fail to open the required path, the endodontist uses smaller stainless steel instruments in the same sequence until reaching the apex 1566 of the root canal 1512 ( FIG. 15C ).
[0199] Once the initial path 1555 is enlarged, at step 2060 , the initial path 1555 is gradually enlarged manually using sequentially hand operated stainless steel instruments with cutting and non-cutting tips from No. 8 or 10 until No. 20 of approximately 2% taper (1 st category 1 st class). The introduction of the instrument with a cutting tip is followed by the use of the same instrument with a non-cutting tip. Alternatively, if possible, a NiTi instrument also selected from the 1 st category, 1 st class, No. 20 with an approximate 4% taper and a cutting tip 1525 followed by the same instrument with a non-cutting tip (e.g., 1633 B), may be introduced.
[0200] Once the initial path 1555 has been enlarged to the desired dimensions, the endodontist then uses, at step 2070 , electrically operated NiTi instruments 1540 selected from the 1 st category, 1 st class, and instruments of the 2 nd category, with a non-cutting tip (e.g., 1633 B), followed by the use of instruments 1540 of the 3 rd category, with a non-cutting tip. In performing this step 2070 , the endodontist sequentially uses in increasing order the instruments 1540 starting with instruments selected from the 1 st category, 1 st class, No. 10 to No. 20 with an approximate 2% taper, and then, instruments from No. 20 to No. 25 of approximately 2% taper of the 2 nd category and finally instrument No. 20 or 25 with an approximate 4% taper of the 3 rd category at the apex 1566 .
[0201] As illustrated at step 2080 and also in FIG. 14E , upon completion of step 2070 as described earlier, the endodontist clears the widened root canal of any debris, as is known in the field, in preparation for the final obturation step.
[0202] As illustrated at step 2090 and also in FIG. 14F , the endodontist obturates the root canal with the appropriate filling material 1446 , as is known in the field.
[0203] According to the another embodiment of the present invention, it is possible to directly reach the apex 1566 , after step 2060 , by using electrically operated NiTi instruments selected from the 1 st category, 1 st class with a non-cutting tip (e.g., 1633 B), in increasing order from No. 10 with an approximate 2% taper to No. 20 with an approximate 4% taper, followed by instruments of the 2 nd and 3 rd categories.
[0204] According to yet another embodiment of the present invention, in less difficult cases, the endodontist may be able to directly reach the apex 1566 , after step 2040 , by using electrically operated NiTi instruments selected from the 1 st category, 1 st class with a non-cutting tip (e.g., 1633 B), starting by enlarging the piercing with a No. 20 instrument having an approximate 4% taper. The process is resumed by using, in increasing order, instruments selected from the 1 st category, 1 st class, from No. 10 with an approximate 2% taper, to No. 20 with an approximate 4% taper of the 1 st category, 1 st class with a non-cutting tip, followed by non-cutting tip instruments of the 2 nd and 3 rd categories, as deemed appropriate by the endodontist.
[0205] It is worth noting that the root canal is irrigated with sodium hypochloride and EDTA (Ethylenediaminetetraacetic acid) at each relevant step of process 2000 .
[0206] The following X-Rays ( FIGS. 33 through 36 ) provide supporting illustrations of this novel process 2000 :
[0207] FIG. 24A shows a broken file in tooth no. 46 blocking the totality of the root canal. FIG. 24B shows the bypassing of the broken file and the piercing of the hypercalcification and reaching the apex with the new instrument according to the present invention. FIG. 24C shows the fully hermetic obturation of the treated root canal.
[0208] FIG. 33A shows an incomplete root treatment of tooth no. 35 due to hypercalcification blocking the third apical of the root canal. FIGS. 33B, 33C , and 33 D show the piercing of the old resistant paste and progressively piercing the hypercalcification with the new instrument reaching the apex, according to the present invention.
[0209] FIG. 34 shows a fully hermetic obturation of tooth no. 46 after piercing a hypercalcification and passing through an accentuated curved line.
[0210] FIG. 35 shows a fully hermetic obturation of tooth no. 47 after piercing a hypercalcification and passing through an accentuated curved line.
[0211] FIG. 36A shows a false canal and an incomplete root treatment of tooth no. 35 due to hypercalcification blocking about half the root canal. FIGS. 36B and 36C show the progressive piercing of the hypercalcification with the new instrument reaching the apex, according to the present invention.
[0212] IV—Method of Penetrating Root Obstructions Resulting from Curved Root Canals
[0213] As illustrated in FIG. 13 , the instruments of the present invention may be used to penetrate root obstructions resulting from curved root canals. In this event, the instruments of the 2 nd category may be used followed by the instruments of the 3 rd category, until the apex of the root canal is reached, with at least an instrument No. 20 having an approximate 4% taper. In case of difficulty, instruments selected from the 1 st category, 2 nd class are used, starting in increasing order from No. 8 to No. 15, with an approximate 2% taper followed by the instruments of the 2 nd and 3 rd categories.
[0214] The following X-Rays ( FIGS. 34, 35 ) provide supporting illustrations of this novel process:
[0215] FIG. 34 shows a fully hermetic obturation of tooth no. 46 after piercing a hypercalcification and passing through an accentuated curved line.
[0216] FIG. 35 shows a fully hermetic obturation of tooth no. 47 after piercing a hypercalcification and passing through an accentuated curved line.
[0217] V—Method of Bypassing Root Obstructions Resulting from a Shoulder
[0218] With reference to FIG. 16 , it comprises FIGS. 16A, 16B, and 16C and illustrates an exemplary tooth 1600 having a root canal 1612 that is obstructed by a shoulder 1610 . With further reference to FIGS. 21A and 21B , the treatment method 2100 is performed according to the following steps:
[0219] As further illustrated in FIG. 16A , the endodontist enlarges at step 2110 of FIG. 21A , the root canal 1612 of the tooth 1600 by using a manual instrument selected from the 1 st category, 2 nd class, No. 8 with an approximate 2% taper, in increasing order to No. 15 with an approximate 2% taper, in order to reach the shoulder 1610 . For the purpose of illustration only, FIG. 16A shows an enlarged view of a cutting tip 1633 A, while FIG. 16C shows an enlarged view of a non-cutting tip 1633 B.
[0220] The endodontist then, at step 2120 , further enlarges the root canal 1612 using electrically rotating instruments selected from the 2 nd category, starting with files No. 10 and an approximate 2% taper, in an increasing order to No. 20 with an approximate 2% taper, up to the shoulder 1610 .
[0221] The endodontist continues to enlarge the root canal 1612 at step 2120 , using electrically rotating instruments selected from the 3 rd category, starting with files No. 20 to 25 with an approximate 4% taper, and continuing with files No. 25 with an approximate 6% taper, whenever possible, until the shoulder 1610 is reached. Preferred results were obtained with a No. 20 instrument with an approximate 4% taper.
[0222] Once the portion of the root canal 1612 up to the shoulder 1610 has been widened to the desired dimensioned, the endodontist continues at step 2130 by creating a path 1655 through the shoulder 1610 using manual NiTi instruments 1620 selected from the 1 st category, 1 st class, No. 20 with an approximate 4% taper and a cutting tip 1633 , by exerting a manual force in a push and pull motion along the arrow F. Thereafter, the instrument 1620 is withdrawn. The relatively large cross sectional surface of the cutting tip 1633 A avoids opening a false canal when exerting a relatively high manual force.
[0223] At step 2140 , the endodontist enlarges the path 1655 using a manual NiTi instrument selected from the 1 st category, 1 st class, No. 20 having an approximate 4% taper and a non-cutting tip 1633 B in order to preserve the opened path 1655 .
[0224] In case of difficulty in enlarging the path 1655 , the endodontist uses a manual stainless steel instrument selected from the 1 st category, 1 st class, No. 20 having an approximate 2% taper with a cutting tip to penetrate the shoulder 1610 in a push and pull motion. Thereafter, it is recommended to manually enlarge the newly opened path 1655 using a manual stainless steel instrument selected from the 1 st category, 1 st class, No. 20 having an approximate 2% taper with a non-cutting tip 1633 B.
[0225] Still at step 2140 , the endodontist continues to enlarge the path 1655 using a manual NiTi instrument selected from the 1 st category, 1 st class, No. 20 having an approximate 4% taper and a cutting tip 1633 . A manual NiTi instrument selected from the 1 st category, 1 st class, No. 20 and an approximate 4% taper with a non-cutting tip 1633 B, may be used in order to preserve the newly opened path 1655 .
[0226] In case of difficulty in penetrating the shoulder 1610 , the endodontist uses a manual stainless steel instrument 1620 selected from the 1 st category, 1 st class, No. 15 having an approximate 2% taper and a cutting tip 1633 , in order to penetrate the shoulder 1610 . This step is followed by the use of a manual stainless steel instrument 1620 selected from the 1 st category, 1 st class, No. 15 having an approximate 2% taper with a non-cutting tip 1633 B, in order to preserve the newly opened path 1655 . In case the abovementioned instruments 1620 fail to open the required path 1655 , the endodontist may use smaller stainless steel instruments 1620 in the same sequence until reaching the apex 1650 .
[0227] Still at step 2140 , the endodontist further enlarges the opened path 1655 manually until the introduction of stainless steel instruments selected from the 1 st category, 1 st class, No. 20 with an approximate 2% taper (alternatively NiTi instrument No. 20 with an approximate 4% taper) having a cutting tip 1633 A and then a non-cutting tip 1633 B, is made possible.
[0228] As further illustrated in FIG. 16C , once the path 1655 has been enlarged to the desired dimensions, the endodontist then uses, at step 2150 , electrically operated NiTi instruments 1630 selected from the 1 st category, 1 st class, 2 nd category, with a non-cutting tip 1633 B, followed by the use of a non-cutting tip instrument 1630 of the 3 rd category. In performing this step 2150 , the endodontist sequentially uses, in increasing order, the instruments 1630 starting with instruments selected from the 1 st category, 1 st class, No. 10 to No. 20 with an approximate 2% taper, and then instruments from No. 20 to No. 25 of the 2 nd category and finally instrument No. 20 or 25 with an approximate 4% taper of the 3 rd category at the apex 1650 .
[0229] As illustrated at step 2160 and also in FIG. 14E , upon completion of step 2140 as described earlier, the endodontist clears the widened root canal of any debris, as is known in the field, in preparation for the final obturation step.
[0230] As illustrated at step 2170 and also in FIG. 14F , the endodontist obturates the root canal with the appropriate filling material 1446 , as is known in the field.
[0231] According to the another embodiment of the present invention, it is possible to directly reach the apex 1650 , following step 2140 , by using electrically operated instruments selected from the 1 st category, 1 st class, provided with non-cutting tips, in an increasing order from files No. 10 with an approximate 2% taper to files No. 20 with an approximate 4% taper, followed by instruments of the 2 nd and 3 rd categories as deemed appropriate by the endodontist.
[0232] According to yet another embodiment of the present invention, in less difficult cases, after enlarging the path 1655 by a manual NiTi instrument No. 20 (1 st category, 1 st class) having an approximate 4% taper and a non-cutting tip (e.g., 1633 B) the endodontist, may be able to directly reach the apex 1650 by using electrically operated non-cutting tip NiTi instruments, starting by enlarging the path 1655 with a file No. 20 having an approximate 4% taper (1 st category, 1 st class) then using in increasing order, non-cutting tip instruments selected from the 1 st category, 1 st class, from No. 10 to No. 20 having an approximate 2% taper and then No. 20 with an approximate 4% taper (1 st category, 1 st class), and finally using instruments Nos. 20 to 25 having an approximate 2% taper of the 2 nd category followed by instruments No. 20 or 25 having a 4% taper of the 3 rd category.
[0233] It is worth noting that the root canal is irrigated with sodium hypochloride and EDTA (Ethylenediaminetetraacetic acid) at each relevant step of process 2100 .
[0234] The following X-Rays ( FIGS. 25 and 37 ) provide supporting illustrations of this novel process 2100 :
[0235] FIG. 25A shows a hypercalcification, a shoulder, and a broken file in the mesial canals of tooth no. 36. FIG. 25B shows the broken file. FIG. 25C shows the bypassing of the broken file, the penetration of the shoulder and the piercing of the hypercalcification in the 2 nd mesial canal and reaching the apex with the new instrument, according to the present invention. FIG. 25D shows the fully hermetic obturation of the treated root canal.
[0236] FIG. 37A shows a blockage in the mesial canal of tooth no. 16 due to a shoulder. FIG. 37B shows the elimination of the shoulder with the new instrument reaching the apex, according to the present invention.
[0237] VI—Method of Penetrating Root Obstructions Resulting from a Previous Root Canal Treatment
[0238] With reference to FIG. 17 , it comprises FIGS. 17A and 17B and illustrates an exemplary tooth 1700 having a root canal 1712 that is blocked or obstructed by, for example a residual, hardened paste 1710 from a previous root canal treatment. With further reference to FIGS. 22A and 22B , the treatment method 2200 is performed according to the following steps:
[0239] As further illustrated in FIG. 17A , the endodontist opens the root canal 1712 at step 2210 of FIG. 22A using instruments 1720 selected from the 1 st category, 2 nd class, starting with file No. 10 with an approximate taper 2%, in order to create an initial path 1733 in the existing residual paste 1710 , using an instrument 1725 with a cutting tip, to a depth of approximately 2 mm to 3 mm, using an appropriate softening agent.
[0240] At step 2220 , the endodontist enlarges the opened initial path 1733 with instruments 1720 selected from the 2 nd and 3 rd categories.
[0241] At step 2230 , the endodontist pierces again the residual paste 1710 , through the initial path 1733 , using an instrument 1720 selected from the 1 st category, 2 nd class, file No. 15, to an additional depth of approximately 2 mm-3 mm.
[0242] At step 2240 , the endodontist enlarges the width of the initial path 1733 using instruments 1720 selected from the 2 nd and 3 rd categories.
[0243] With further reference to FIG. 17C , and to step 2250 of FIG. 22B , the endodontist pierces again the widened initial path 1733 using an instrument 1730 selected from the 1 st category, 2 nd class, file No. 15, with a possible recourse to file No. 10 of the 1 st category, 2 nd class, until the apex 1750 is reached.
[0244] At step 2260 , the endodontist enlarges the opened path 1755 with instruments selected from the 2 nd and 3 rd categories in preparation for the obturation step.
[0245] In the event an unexpected obstruction is faced inside the resistant paste, the aforementioned steps of process 2200 will be used depending on the nature of the encountered obstruction, i.e. fractured instrument, hypercalcification, curved root canal or shoulder.
[0246] It should be clear that if the obstruction within the root canal includes a resistant, residual paste 1710 , the process 2000 described earlier in connection with FIG. 20 relating to the piercing of the hypercalcification, can be used, in the same sequence from step 2030 through step 2070 .
[0247] As illustrated at step 2270 and also in FIG. 14E , upon completion of step 2260 as described earlier, the endodontist clears the widened root canal of any debris, as is known in the field, in preparation for the final obturation step.
[0248] As illustrated at step 2280 and also in FIG. 14F , the endodontist obturates the root canal with the appropriate filling material 1446 , as is known in the field.
[0249] It is worth noting that the root canal is irrigated with sodium hypochloride and EDTA (Ethylenediaminetetraacetic acid) at each relevant step of process 1900 .
[0250] The following X-Rays ( FIGS. 27, 33, 37, 38 ) provide supporting illustrations of this novel process 2200 :
[0251] FIG. 27A shows three broken files with resistant paste in tooth no. 35 blocking the totality of the root canal. FIG. 27B shows the bypassing of the three broken files and the piercing of the resistant paste with the new instrument reaching the apex, according to the present invention. FIG. 27C shows the fully hermetic obturation of the root canal.
[0252] FIG. 33A shows an incomplete root treatment of tooth no. 35 due to hypercalcification blocking the third apical of the root canal. FIGS. 33B, 33C , and 33 D show the piercing of the old resistant paste and progressively piercing the hypercalcification with the new instrument reaching the apex, according to the present invention.
[0253] FIG. 37A shows a blockage in the mesial canal of tooth no. 16 due to a shoulder and a resistant paste. FIG. 37B shows the elimination of the shoulder and the piercing of the resistant paste with the new instrument reaching the apex, according to the present invention.
[0254] FIG. 38A shows a false canal and a resistant paste in tooth no. 37. FIG. 38B shows the avoidance of the false canal and the piercing of the resistant paste with the new instrument reaching the apex, according to the present invention.
[0255] It is to be understood that the specific embodiments of the invention that have been described are merely illustrative of certain application of the principle of the present invention. Numerous modifications may be made to the present instruments and methods described herein without departing from the spirit and scope of the present invention. | Instruments and associated methods for performing endodontic treatment and that demand less time and fatigue onto the dentists and patients, while presenting the following accomplishments: debride the root canals in three dimensions and performing the optimal treatment; shape the root canals to facilitate the irrigation; these instruments are resistant to breakage and pressure while operating at high speed and torque; the instruments are capable of bypassing most obstacles, broken files, hypercalcification, curved roots canals, shoulders, and residual resistant pastes; and they present an alternative to arduous and expensive surgeries like endodontic or implant surgeries. As a result, they prevent fractures and procedural errors in making false canals or perforations of the root canals. | 0 |
This is a division of application Ser. No. 429,819 filed Jan. 2, 1974, which was a continuation-in-part of application Ser. No. 295,019, filed Oct. 4, 1972, now abandoned.
FIELD OF INVENTION
The present invention relates to the manufacture of slide fastener elements, namely the elements comprising a tape of flexible material carrying a row of coupling members adapted to be coupled with another similar row by means of a control slide or tab.
DESCRIPTION OF THE PRIOR ART
Various methods of manufacturing such elements have already been proposed. According to one of these known methods the coupling members of the same rows are obtained by means of a continuous filament by so shaping this filament as to form a series of loops adapted to project from one edge of the corresponding supporting tape, the tape edges advantageously comprising thicker portions or other deformations adapted to facilitate the proper coupling with similar members carried by another identical element. To this end, the filament employed for making the coupling members may be caused to follow a coil or meander path.
In most instances these rows of coupling members thus obtained are manufactured independently of the corresponding carrier tapes, and subsequently secured thereto by suitable means, notably by sewing.
But according to a specific manufacturing method each row of coupling members is obtained during the very operation consisting in weaving the corresponding tape, so that the filament utilized therefor is woven as a weft yarn with the warp yarn of this tape. This method is advantageous in that it eliminates the subsequent operation consisting in fixing the rows of coupling members to the corresponding carrier tapes.
However, the presence of this filament in the tape texture tends to produce a certain tape distortion. This effect is due to the fact that the filament, having different physical properties in comparison with those of the textile yarns of the tape, comprises loops all wound in the same direction.
SUMMARY OF THE INVENTION
It is therefore the object of the present invention to provide a novel method of manufacture intended to eliminate this drawback.
This method is characterised essentially in that, during the weaving of the tape of the element, two separate filaments are inserted into the texture for constituting the fastening or coupling members propers by engaging by turns one and the other filaments between the warp yarns, at spaced intervals, to constitute at each point of insertion a transverse loop wound in one direction for one filament and in the opposite directions for the other filament, and meanwhile these filaments are disposed in the longitudinal direction on the side opposite to the coupling members proper, whereby these filaments constitute two variable-pitch helices of which the loops wound in opposite directions are imbricated, every other loop belonging to the same helix.
The element thus obtained is advantageous in that it is perfectly symmetrical and free of any tendency to twist up since both fastener filaments are wound in opposite directions. Moreover, the control tab can be engaged indifferently in one or the other longitudinal direction on two sections of this element for obtaining a complete slide fastener.
The present invention is also concerned with an apparatus for carrying out the method broadly disclosed hereinabove. This apparatus comprises a weaving loom arranged to provide laterally the space necessary for the operation of two needles adapted to introduce the two fastener filaments, said needles being disposed in close vicinity of the weft yarn weaving member, across the movable sheet of warp yarns, whereas a retractable member adapted to retain each loop formed by the two filaments registers with one of the two edges of the sheet of warp yarns. On the other hand, adequate control means are provided for alternatively engaging one and the other needles and insert the two filaments beyond the corresponding edge of the warp yarns, and retracting said needles to a fixed waiting position, and meanwhile bringing the retaining member to its operative position and retracting same from this position.
Of course, this invention is also concerned with the slide fastener elements obtained by carrying out the method of this invention, preferably by means of the apparatus broadly described hereinabove.
BRIEF DESCRIPTION OF THE DRAWINGS
However, other specific features and advantages of this invention will appear as the following description proceeds with reference to the attached drawings given by way of illustration and showing diagrammatically the coupling members with a relative spacing considerably greater than the spacing obtaining in actual practice, in order to facilitate the understanding of the invention. In the drawings:
FIG. 1 is a diagrammatic plane view from above showing the manufacture of a fastener element according to this invention;
FIG. 2 is a cross-section taken along the line II--II of FIG. 1, showing the members utilized for weaving the two fastener filaments;
FIG. 3 is a similar view showing the same members in different working positions;
FIG. 4 is a diagrammatic perspective view showing a fastener element obtained according to the teachings of this invention;
FIG. 5 is a diagrammatic plan view from above of a slide fastener consisting of two elements manufactured according to the teachings of this invention;
FIG. 6 is a section taken along the line VI--VI of FIG. 5;
FIG. 7 is a plane view from above showing a modified form of embodiment of the method of this invention;
FIG. 8 is a diagrammatic perspective view of the fastener element obtained by carrying out the modified method illustrated in FIG. 7, and
FIG. 9 is a view similar to FIGS. 2 and 3 showing a modified form of embodiment of the manufacturing method of this invention.
FIG. 10 is a perspective view of a loom for carrying out the method of this invention;
FIG. 11 is a part-sectional, part-elevational view of the device controlling the needles for inserting the two filaments;
FIG. 12 is a diagram illustrating an ancillary device for tensioning one of these filaments;
FIG. 13 is another diagram showing in plane view from above the device for controlling the movable loop retaining member associated with each filament;
FIG. 14 is a view similar to FIGS. 2 and 3, illustrating a modified embodiment of the method of this invention, and
FIG. 15 is a part-sectional, part-elevational view showing the device for controlling the needle for inserting the two filaments in this modified embodiment.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The apparatus employed for carrying out the method of this invention comprises a weaving loom adapted to be operated for weaving this tape. Preferably, a needle loom is used, advantageously a single-needle loom capable of operating at high production rates.
Thus, for instance, a needle loom such as the "BONAS ES 1/D4" manufactured by the British Company BONAS MACHINE COMPANY LIMITED of Sunderland (G.-B.). This loom, converted for operation according to the method of this invention, is illustrated in FIG. 10.
In this loom, the various warp yarns 1 constitute initially a sheet travelling in the direction of the arrow F past the needle 2 used for weaving the weft yarn 3. This yarn comprises simple loops disposed along one of the edges 4 of the relevant tape 5. However, on the opposite edge 6 a needle of known type, such as a latch needle 7, is provided for interconnecting the various warp yarn loops, as illustrated in FIG. 1.
In the vicinity of the position occupied by the weft yarn needle 2 two members adapted to insert two filaments A and B are provided. Thus said members are in the area where the warp yarns 1 are still divided into two separate sheets through the action of the loan heddles. The two filaments A and B are adapted to constitute the coupling members of the corresponding fastener element. The members adapted to insert said filaments consist of a pair of needles 10 and 11, respectively, disposed on either side of the sheets formed by the warp yarns, in front of one and the other face of these two sheets.
It may be noted more particularly that, due to their specific arrangement, these two needles are capable of forming, with one and the other filaments, loops wound in opposite directions, as will be described in detail presently.
These needles are of course movable and controlled by mechanical means designed for alternatively engaging one and then the other needle inbetween the two sheets of warp yarns, beyond the edge 4 of the tape, then returning the needle backards in order to form each time a loop with the corresponding filament.
To this end, the present apparatus comprises likewise a retractable retaining member 12 adapted to retain in position the loop formed by each filament as the corresponding needle 10 or 11 accomplishes its return or backward stroke. However, this member is subsequently retracted for resuming its operative position when the next loop is about to be made by means of the other filament of the fastener.
In the example illustrated, the two needles 10 and 11 are advantageously elbow, bent or curved needles and each of them is rotatably mounted about a pivot pin 13 or 14 substantially parallel to the warp yarns. These needles are perfectly symmetric and as will be explained presently their movements are also symmetric in relation to the median plane of the slide fastener.
Beyond their elbow, these needles 10 and 11 comprise each a groove 15 formed on the side opposite to the relevant axis of rotation, this groove 15 leading to the hole 16 of each needle and adapted to receive the relevant fastener filament A or B.
These two needles are controlled by cam means or any other suitable mechanism. The same applies to the loop retaining member 12 of the two fastener filaments.
FIG. 11 illustrates a typical embodiment of the device for controlling the movements of the pair of needles 10 and 11. The rods 13 and 14 carrying these needles are rotatably mounted in bearings carried by a support 45 secured to the frame structure 46 of the loom shown in FIG. 10. Each rod 13, 14 carries a lateral arm 28 connected through a link 31 to a control member 30 adapted to pull or push said link. The two control member thus provided engage a pair of rotary cams 32 carried by a shaft 33. This shaft 33 is operatively connected to the end of one of the rotary shafts 47 of the loom.
Spring means, not shown, constantly urge the control members 30 in engagement with the corresponding cams. The cam contours are such that when actuate these control members 30 in order to cause with the proper timing the rotation of one of the two needles 10 or 11 in one direction then in the opposite direction, whereafter a similar action is exerted on the other needle, and so forth as will be explained in detail presently.
FIG. 13 illustrates a typical embodiment of a device for controlling the movable member 12 adapted to retain the loops of the two fastener filaments. This member is carried by the cranked end of a rod 48 slidably mounted in a guide member 49 secured to the top of the loom.
The opposite end of this rod is resiliently urged for engagement with a control cam 50 rotatably driven from a shaft coupled to one of the power shafts of the loom. A spring 51 is provided to this end.
Now the cam contour is such that at the proper time the cam 50 causes the retaining member 12 to be inserted into the loops formed by one of the fastener filaments A or B, whereafter this member 12 is retracted as another loop is formed by the other filament, and so forth.
It is not compulsory to provide a specific device for feeding the fastener wires A and B. In fact, these may be simply pulled as necessary by the fastener tape during the weaving operation, inasmuch as the fastener wires A and B are incorporated in said tape and the latter is driven forwards in the loom.
However, in this case it is nevertheless necessary to provide a device for braking one or the other filaments or wires A and B and thus tensioning them and properly shape the loops.
The arrangement is such that at predetermined time intervals the needle 10 penetrates between the two sheets of warp yarns 1 for example at an intermediate point of the width thereof. To facilitate the penetration of both needles at this specific point, the conventional cam means controlling the heddles for separating the warp yarns of the two sheets may be modified, at least as far as some of these heddles are concerned.
In fact, this modification may involve only the warp yarns 1a located along the selvedge of the tape and between which the fastener filaments A and B are inserted.
The cams controlling the heddles associated with these warp yarns 1a are then modified with a view to accentuate the separation of these yarns, as illustrated in FIGS. 2 and 3 and thus facilitate the engagement of one of the needles 10 or 11 between these yarns. On the other hand, the cams controlling the heddles of the other warp yarns 1 may be modified with a view to reduce the relative spacing of these yarns at the same point and for the same purpose, but it will readily occur to those conversant with the art that this last-mentioned modification is quite conventional in a weaving loom.
The insertion of the needle 10 takes place of course by means of a rotational movement of said needle 10 as shown by the arrow F 2 . Said needle will thus cause the filament A to form the first half 17 of the loop to be obtained at this position. When the needle 10 has reached its outermost position beyond the edge 4, the retaining member 12 is brought to its operative position as shown in FIG. 2. Then, the needle 10 is caused to recede due to its rotation in the direction of the arrow F 3 , so as to lay down locally the other half 18 of the loop to be formed at this location.
During this operation, the retractable member 12 retains in position the loop thus formed, so that it cannot be pulled backwards during the return movement of the needle 10 to its inoperative position. However, this retaining member is also adapted to permit a distortion of the filament section in order to constitute a coupling member 19 of the fastener during the same manufacturing process.
In fact, the traction exerted on the filament in the backward direction causes this filament to be elongated against the retaining member 12. Now this elongation is attended by a modification in the cross-sectional shape of the filament and therefore by the development of two lateral projections therein, as illustrated in FIG. 1. Thus, a coupling member is obtained which is adapted to catch identical members formed along the other fastener element during the actual use of imbrication of the fastener elements.
FIG. 12 illustrates a typical embodiment of a device suitable for tensioning each fastener filament A or B, and for tensioning same at the end of each loop.
This device comprises a holding clamp consisting of a movable jaw 34 registering with a fixed jaw 35, on either side of the passage of the corresponding wire 8. The movable jaw 34 is carried by the rod 36 of a control cylinder 37.
Downstream of this clamp, i.e. on the side located in the direction of the point of insertion of the wire 8 into the tape during the weaving operation, a movable member adapted to tighten the wire loop formed downstream is provided. This member consists of a roller 38 carried by a rod 39 of a control cylinder 40. This roller 38 registers with the wire A or B and can thus push the latter back and cause same to form a loop 41 between the pair of fixed rollers 42.
As a consequence of the formation of this loop, the wire A or B is pushed backwards so as to absorb any slack therein while tensioning the loop formed by this wire.
Of course, the jaw 34 must be in its clamping position during this phase.
The operations of cylinders 37 and 40 is controlled by suitable means in synchronism with the other component elements of the machine.
The elongation of each filament A and B on said retaining member 12 may if desired be completed by the application of heat to well-defined spots, in order to facilitate the formation of these coupling members 19, the fastener elements consisting advantageously of thermoplastic material. This local heating action may be produced by using jets or heated air or an inert hot gas, such as nitrogen, or any other suitable and known means. Thus, the retractable retaining member may be connected to a suitable generator of supersonic waves capable of heating the filament.
When the first looping needle 10 has been withdrawn, it remains stationary in its inoperative position as shown in FIG. 3. But in this position it permits the free winding off of filament A in the direction of the warp yarns, as these yarn continue their forward or feed movement. Thus, a connecting portion 20 between two successive transverse loops can be completed.
However, during this time, the needle 2 of the weaving loom makes one or several picks with the weft yarn.
Then, the second looping needle 11, which remained stationary during the above-described operation, becomes operative in turn by introducing the other filament B into the gap between the two sheets of warp yarns. The mode of operation of this needle is then the same as that of the first looping needle 10, with the difference however that the winding of the loops formed with this filament B takes place in the reverse direction in comparison with the winding of the loops formed with filament A. This is due to the fact that the two needles 10 and 11, having the same shape, are disposed in opposition to each other on either side of the sheet of warp yarns.
Thus, during its operative stroke (in the direction of the arrow F 4 ) the second needle 11 will lay down the first side or portion 21 of the loop to be formed at this location by filament B. But it should be noted that this loop side is then located at the bottom, considering the planes of FIGS. 2 and 3, whereas the first side 17 of the loops formed with filament A were placed at the top.
When this needle 11 has attained its endmost position illustrated in FIG. 3, the retaining member 12 resumes its operative position previously abandoned after the return stroke of the first looping needle 10 towards its inoperative position. Then the second needle 11 resumes by itself its inoperative position by rotating in the direction of the arrow F 5 , so as to lay down the second side 22 of the loop. But, at the same time, a coupling member 19 is formed on the projecting end of this loop, as described hereinabove in connection with the mode of operation of the first needle 10.
The second looping needle 11 then remains stationary in its inoperative position illustrated in FIG. 2, while permitting the free winding off of filament B in order to form a connecting portion 23 between the two transverse and successive loops formed with said filament B.
During this period, the needle 2 of weft yarn 3 makes one or several picks, and subsequently the first looping needle 10 resumes its operative position for making another loop with filament A, and so forth.
Thus, transverse loops are formed alternatively with one and the other filaments A, B, by winding these filaments in opposite directions. Besides, the connecting portions 20 and 23 between the successive transverse loops formed from the two filaments A and B are located on one and the other faces of the corresponding tape. As can be seen in FIG. 6 these filaments A and B will thus form identical projections on the two faces of the tape, in relation to the median plane of the fastener element.
In this respect, it may be noted that the two filaments A and B are not woven with the warp and weft yarns of the tape, as observed in certain known prior art manufacturing processes. In fact, these filaments are simply inserted in between the warp and weft yarns. Moreover, these filaments comprise both transverse portions, namely the transverse loops, and longitudinal portions, namely the connecting portions or sections 20 or 23.
Due to the particular method of distributing the filaments A and B, each filament forms along the tape selvedge or marginal portion a variable-pitch coil constituting a series of loops disposed in transverse planes and connecting elements 20, 23 extending in the longitudinal direction. But, as already explained in the foregoing, the transverse loops of these two coils are wound in opposite directions.
One of the essential advantages deriving from the method of this invention lies in the fact that the winding of the loops formed with the two filaments in opposite directions affords a positive balance between the possible tendency to twist up, which might develop as a consequence of the winding of these filaments between the warp yarns and the weft yarns of the tape.
Another advantageous features is that the elements thus obtained is perfectly symmetrical. Thus, it is possible to cut out two sections of this element and assemble these sections with each other after turning them in opposite end to end relationship. Besides, FIGS. 5 and 6 illustrate a complete slide fastener thus obtained by assembling two sections of a same fastener element manufactured according to the teachings of this invention.
Another advantageous feature consists in that the control tabs can be set in position in one or the other direction, indifferently. This is also due to the perfect symmetry of the fastener elements obtained by carrying out the method of this invention. Now, this easy tab fitting possibility constitutes an important advantage notably in the manufacture of certain ready-made garments.
Another advantageous feature characterising this invention relates to the improved tab guiding section afforded by its method. In fact, by virtue of the symmetry of the element section thus obtained two identical projecting beads are formed on one and the other face of this section. Thus, these beads act as guide rails for the slide or tab on one end and the other face of the element. Now in most hitherto known slide fasteners types only one of the two faces comprises such projecting guide bead.
Another reason of the improved tab guiding action obtained with the present invention is due to the fact that on both faces of the slide fastener element the connecting portions between the transverse loops formed by the aforesaid filaments A and B are somewhat off-set. In fact, when on one of the tape faces a connecting portion leads to a transverse loop, thus breaking the continuity of the tab guiding slideway, the necessary guiding action is continuous on the other face of the tape, due to the presence of the corresponding filament.
Of course, the manufacturing method of this invention should not be construed as being strictly limited to the steps described hereinabove with references to the apparatus illustrated in FIGS. 1 to 3 of the drawings. Thus, FIGS. 7 and 8 illustrate a modified form of embodiment of this method which is intended for improving the holding in position of the transverse loops formed by the two fastener filaments. This result is obtained by properly anchoring each loop at the base, i.e. where each loop merges into the corresponding connecting portions 20 or 23.
This anchoring action is produced by means of another loop 24 formed by means of the weft yarn 3 at this location. This is obtained by causing the premature return of the weft yarn on itself before attaining the corresponding edge 4 of the tape, at the location of each transverse loop of the two filaments A and B of the corresponding fastener element.
The premature return of the weft yarn 3 at 24 to the bottom of the turns formed by the fastener wire is obtained by modifying the manner in which the warp yarns 1a provided along the selvedge are "lifted". In fact, it is only necessary that all the selvedge warp yarns 1a be lowered at the location corresponding to the time of the positive stroke of needle 2 so that the weft yarn 3 can pass above these warp yarns and then, during the return stroke, this yarn 3 will not find any obstacle before attaining the very base of the fastener wire, so that it will form a loop 24 only at this point.
As a matter of fact, this technique is well known and conventional in the art of passementry, when patterns are formed on only one portion of the tape width.
With this modification in relation to the other warp yarns 1b (which takes place only at the proper time) the weft yarn 3a will form a loop 24 at the root of each transverse loop of the two fastener filaments as illustrated in FIGS. 7 and 8. Thus, the loops formed by means of the fastener filament are safely anchored while avoiding notably any possibility of untimely slippage thereof in the transverse direction.
Instead of disposing the needles for introducing the two filaments A and B on either side of the movable sheet for warp yarns 1, it would also be possible to dispose said needles in front of a same face of this sheet, provided that said needles are off-set to each other in the longitudinal direction. In this case it would be necessary of course to provide unequal time intervals between the moments whereat said needles are rendered operative.
On the other hand, in this case it would be necessary to use two needles 10a and 11a (see FIG. 9) of different types, capable of producing the winding in opposite directions of the loops formed with one and the other filaments; in this case, one needle, for example needle 11a, may be identical with the above-described needles 10 or 11 of the preceding example, and comprise a groove 15 on the side opposed to its pivot axis. As to the other needle 10a, it would then comprise a groove but on the opposite side, i.e. towards the pivot 14, in order to permit the winding the loops in the other direction with respect to the winding direction of needle 11a.
Of course, many other modifications may be contemplated in connection not only with the various steps of the manufacturing method of this invention but also with the component elements of the apparatus employed for carrying out this method, and with the fastener elements themselves.
Possibly, the two sides of each loop formed by means of the fastener filaments may have a different relative position in lieu of the direct superposition contemplated in the above-described examples.
The coupling members could also be manufactured differently. Thus, instead of forming these members by pulling the retaining member 12, it would be possible to provide preliminary distortions on the fastener elements at properly spaced locations so that these distortions lie on the end of the projecting loops formed by these filaments during their insertion in the course of the tape weaving operation.
But, conversely, it would also be possible to form these coupling members after making the loops of the two fastener filaments and inserting these filaments throught the tape.
Besides, the two fastener filament inserting looping needles contemplated in the examples illustrated could be replaced by rectilinear needles performing simple reciprocating movements, or by any other suitable members capable of positioning the two fastener filaments.
FIGS. 14 and 15 illustrate this modified embodiment.
As clearly shown, in this modified embodiment two separate rectilinear insertion needles 10b and 11b are used; a reciprocating motion is imparted thereto along two oblique axes, instead of a pivotal motion as in the case of the curved needles 10 and 11.
Both rectilinear needles 10b and 11b are disposed in a same plane perpendicular to the general plane Z--Z' of the tape being woven on the loom contemplated therefor. These needles are secured to a pair of movable supports 25a and 25b slidably mounted in a pair of stationary tubular guide members 26 rigid with a bracket 27 secured to the loom frame structure.
These movable supports 25a and 25b for the aforesaid pair of needles are driven through a pair of bent levers 28a, 28b fulcrumed to a pair of fixed pivot pins 29 and driven in turn from push-rods 30a and 30b connected through links 31 to said levers.
These push-rods register with a pair of rotary control cams 32a and 32b carried by a rotary shaft 33 adapted to be coupled to one of the rotary shafts of the loom.
The contour of these cams 32a, 32b is such that they control by turns the movement of needle 10b in the direction of the arrow F 1 so as to insert the corresponding wire into the tape, whereafter this needle is withdrawn and the other needle 11b is moved in the direction of the arrow F 2 to insert the wire carried by this needle into the tape, and finally returning the needle backwards, and so forth.
Of course, these movements are synchronized with those of the retaining member 12 provided along the tape selvedges so as to retain each loop thus formed by means of one and the other of said pair of wires or filaments.
As far as the apparatus employed for carrying out the method of this invention, it may be noted that different types of weaving looms may be used. However, in the case of a needle-type weaving loom, it would be preferable to use a loom type providing the room necessary for mounting the pair of additional needles intended for introducing the fastener filaments, and also for positioning the retaining member 12 and the various corresponding mechanical control means. However, a conventional loom could also be used, notably a loom comprising one or a plurality of shuttles, for introducing the weft yarn. | This method and the apparatus for carrying out same are characterised essentially in that, during the weaving of the tape of the element, two separate filaments are inserted into the texture for constituting the fastening or coupling members propers by engaging by turns one and the other filaments between the warp yarns, at spaced intervals, to constitute at each point of insertion a transverse loop wound in one direction for one filament and in the opposite directions for the other filament, and meanwhile these filaments are disposed in the longitudinal direction on the side opposite to the coupling members proper, whereby these filaments constitute two variable-pitch helices of which the loops wound in opposite directions are imbricated, every other loop belonging to the same helix. | 3 |
TECHNICAL FIELD
The invention relates to collection apparatus for enabling measurement thereof which is precisely positionable.
As an example, electrophotographic copiers may employ coronas for generating specific charges at the photoconductor. These charges are best measured by measuring the resultant current flow to the photoconductor at the precise position it occupies when in use. The collection and position and the resultant measurement must be precise because small differences in corona charge generation result in major differences in copy quality.
BACKGROUND ART
U.S. Pat. No. 4,189,642 describes an insulated rotatable drum carrying a photoconductor supported on a conductive layer. The conductive support layer is connected via slip rings to ground, and when the circuit is opened, and each corona individually operated, current in the conductive support layer may be measured.
Having a drum of floating voltage, i.e., electrically insulated, would result in irregular charge patterns on the photoconductor except for a sheet of conductive backing for the photoconductor, which must be connected to ground. Further, to provide a measurement of each corona individually, when the conductive backing is adjacent all coronas, a control circuit must be provided to individually activate each corona. A control circuit must also open the ground connection for the conductive backing to allow measurement. The resultant arrangement is therefore very expensive and comprises a permanent part of every machine, whereas the measurement to be made is done only occasionally by or for a repair or maintenance technician.
Another arrangement often used in the assembly of copiers is to remove the normal photoconductor and substitute a special insulated drum with conductive areas for measurement purposes.
Special insulated drums or fixtures for testing are not permanent parts of each machine and are therefore less expensive as concerns total cost. However, they are extremely bulky and cannot be easily or conveniently transported by a repair or maintenance technician. Further, any slight difference in size between the test fixture and the photoconductor carrier, creating a difference between the position of measurement and the actual position of the photoconductor which is to receive a charge, would result in an error.
SUMMARY OF THE INVENTION
A planar sensing element is provided, affixed to and supported by a flexible planar support member and having an adhesive, nonresidue material affixed to the reverse side of the flexible planar support member for holding the support member in position against an element at which sensing is to occur and thereby holding the planar sensing element in precise position across its entire area. A shock protection line and circuit is connected between the planar sensing element and ground. Measurements may be made between the planar sensing element and ground or other selected test points.
The resultant device is truly and easily portable and, when affixed to the element at which sensing occurs, is precisely positioned over its entire area thereby giving a more accurate basis for measurement.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic front view of a prior art electrophotographic copier for which the present invention is primarily adapted.
FIG. 2 is a top view of the device of the present invention.
FIG. 3 is a partial side view of the planar members of the device of the present invention.
FIG. 4 is a schematic representation of the electrical circuit of pigtail 56 of FIG. 2.
FIG. 5 is a perspective view of the drum carrier for the photoconductor of the prior art electrophotographic copier of FIG. 1.
FIG. 6 is a perspective view of the drum of FIG. 5 with the device of the present invention in place.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 is a front schematic view of an electrophotographic copier, for example the IBM Series III Copier/Duplicator. The present invention may be advantageously employed to measure corona currents for this prior art or any similar copier.
In the exemplary copier, a scanning mirror system 10 and a moving lens 11 move in synchronism with the rotation of drum 12, having a photoconductor thereon, to place a latent image of stationary original document 13 onto the photoconductor. The drum and photoconductor are sufficiently large enough so that two operative photoconductor panels are arranged on its circumference, so as to be capable of producing two copies for each drum revolution.
As is well known, prior to imaging at 14, the drum is charged by a corona 15. The corona 15 is a high voltage source designed to place a uniform electrostatic charge on the insulated photoconductor. Once charged, the photoconductor rotates into the image path 14. The portions of the charged photoconductor which are exposed to illumination lose their charge so that the charge remains only in the area of the dark image. Since the entire photoconductor was charged, the area surrounding the working area to image the original document 13 need not retain a charge. Therefore, the photoconductor surrounding this working area is erased by erase station 19.
After imaging, the drum's latent image is developed by magnetic brush developer 16. The magnetic brush carries magnetically attracted particles to which toner, primarily carbon, is coated, past the charged photoconductor. Electrostatic effects cause the toner to adhere to the charged areas, thus providing a visible image on the drum surface. Thereafter, the drum's toned visible image is transferred to a sheet of plain copy paper at transfer station 17 by operation of transfer corona 18. The transfer corona 18 provides the proper charge to the reverse side of the sheet of paper to attract the toner particles on the photoconductor to the paper. The paper, now coated with toner in the image area, is then caused to leave the surface of the drum and to follow sheet movement path 20, adjacent vacuum conveyor 21, to hot roll fuser assembly 22. The fuser 22 causes the toner to melt and adhere to the paper.
Hot roll fuser assembly 22 includes a hot roll 37 and a relatively cool backup roll 38. After fusing, the finished copy sheet follows sheet path 33, 34 and is deposited in output tray 29 when the copier is operating in the sheet simplex mode or side two in the duplex mode. When the copier is operating in the duplex mode, side one, the copy sheet follows sheet path 33, 35, and is deposited in duplex bin 36. Thereafter, when operating in the side two duplex mode, these sheets return to the transfer station while following sheet path 32, 28. These sheets are supplied originally from sheet supply bin 23 and 24, which are arranged to adjustably hold cut sheets of plain paper of different sizes, for example, legal and letter size paper, respectively.
After transfer of the toned image from the photoconductor to the sheet, the photoconductor is cleaned as it passes cleaning station 30. Specifically, inasmuch as all of the toner previously adhering to the drum is not removed by the transfer corona, the cleaning station comprises means for removing the remainder of the toner. Thus, the cleaning station includes a cleaning corona 41, similar to the transfer and charge coronas although opposite in polarities, which serves to remove any remaining charge on the photoconductor, an erase lamp 40 to remove optically residual charge on the photoconductor, and a cleaning brush 42. The cleaning corona 41 ensures that the toner will not adhere to the drum so that the toner is easily removed by the brushing of cleaning brush 42 which rotates in a direction opposite to the rotation of drum 12.
The charge placed on the photoconductor by each of the coronas 15, 18 and 41 must provide clear and complete copying.
FIG. 2 illustrates the device of the present invention. The device incorporates a planar strip 50 having an electrically conductive surface or sheet 51 thereon. The device is arranged with tabs 53 and 54 at either end. A pigtail or single electrical wire 56 is affixed to tab 53 by any suitable means such as insulated screw 57 so as to be in electrical contact with electrically conductive surface or sheet 51. The electrical connection may be mechanical or soldered. The pigtail also includes diodes 58 and an electrical connector 59.
Referring to FIG. 3, planar sheet 50 comprises electrically conductive coating, layer or sheet 51, which may be aluminum, supported by a support layer or strip 60 which may be a plastic insulating substance such as Mylar. The plastic strip 60 is coated with a sticky substance 61 that leaves minimal or no residue. A removable plastic or paper strip 63 may be provided to protect the surface 62 of the plastic strip 60 from contamination. Preferably, strip 63 is polyethylene. The strip 63 is shown as partially removed.
An example of adhesive element 61 is "high-tack low-tack" tape marketed by the 3M Company under Part No. "Y9415." The strip is approximately three thousanths (0.003) inches thick and surface 62 comprises the low-tack side of the adhesive tape. This low residue or nonresidue surface is defined as "nonresidue" hereinafter. The conductive layer 51 may comprise a sheet of approximately 21/2 to 5 ten-thousanths (0.00025 to 0.0005) inch of aluminum. In the specific example, the coating 51 comprises a sheet of aluminum adhered to the "high-tack" side of tape 61. Polyethylene has been selected as the preferred material for strip 63 due to its surface tension characteristic which is low relative to that of the adhesive tape 61.
FIG. 4 illustrates schematically the electrical configuration of the diodes 58 in pigtail 56 of FIG. 2. Specifically, diodes 65 and 66 are placed in a front-to-back parallel configuration between connection point 57 and electrical connector 59. This results in a bidirectional low resistance path, the resistance being less than that of the human body so that handling or touching of surface 51 in FIG. 2 will not result in harmful shock. Rather, any excess current resulting from a high voltage build-up would be discharged via diode 65 or 66 to grounded terminal 59. The diodes may be, for example, of the type known as Industry Standard Part. No. 1N914.
FIG. 5 illustrates the photoconductor drum 12 of the copier of FIG. 1. The drum is hollow, having end plates 70 and 71. The photoconductor 72 is wound on reels internal to the drum and is then wrapped about the drum's circumference. A drum seal 74 occupies the space between the point 75 where the photoconductor exits the drum and point 76 where the photoconductor enters the drum.
The strip 50 in FIG. 2 is designed to fit precisely over the drum seal 74 in FIG. 5. When so affixed, the ion current generated by the corona is drawn to conductive surface 51 of strip 50.
FIG. 6 illustrates the device 50 in position on drum 12 of FIG. 5. In FIG. 6, the paper or plastic cover sheet 63 of FIG. 3 has been removed from device 50 and the device placed on drum seal 74 in FIG. 5. The device is thus positioned properly along the entire surface of the drum surface 74. Pigtail 56 on tab 53 of the device is at the end of drum 12 which will be towards the rear of the copier. The device 50 is affixed to the drum when the drum is removed from its working position in the copier. Connector 59 on pigtail 56 is connected to a grounding point on the copier comprising screw 80. The drum 12 is then inserted into the machine and a drum rotated to position the drum seal 74 and, therefore, device 50 immediately adjacent the corona to be tested. Surface 51 of device 50 is thus positioned to collect the ion current generated by the corona being tested. Tab 54 of the device protrudes from the end of drum 12 at the front of the machine, thereby allowing easy access by the repair or maintenace technician.
A measuring device 85 supplied by the repair or maintenance technician includes a grounding lead 86 and a probe 87. The measuring device 85 may comprise any accurate current measuring device, preferably a small portable ammeter. Probe 87, preferably having an alligator clip, is touched to surface 51 on tab 54. Lead 86 is connected to a grounding point on a machine, and the machine, or at least the corona to be tested, is turned on (drum is in a nonrotatable mode during this test). Then, measuring device 85 is observed until a steady state current flow is attained. This current flow is that generated by the corona being tested. Adjustments may then be made to correct any difference between the measured current flow and that desired. These adjustments may take the form of moving the corona closer or further from the drum 12, or adjusting the corona power supply.
Upon completion of the measurement and any appropriate adjustment of the first corona, further coronas may be measured.
The subject device is sufficiently portable and not bulky, so that it may be easily carried by the repair or maintenance technician. However, it is also sufficiently inexpensive that one may be supplied with each copier and stored unobtrusively therein. Further, should its use be required upon installation of new corona parts, a device may be supplied with each such set of parts.
A prime advantage of the device of the subject invention is that it is positioned on the drum actually used by the copier being measured. Thus, there is no size difference, as there might be with a special fixture which is carried by the maintenance or repair technician from machine to machine. The radial position of the measurement is thus precisely controlled to that of the specific machine being measured.
The adhesive nature of the application side of the device 50 ensures that the entire surface of the device is properly and precisely positioned. There is thus no need for a rigid fixture to ensure that no part of the device bends or projects upward from the drum toward the corona. This is important in modern copier technology because the coronas are surrounded by shields which absorb a substantial amount of the corona current. The percentage of the current received by the photoconductor on drum 12 is dependent, therefore, upon the distance of each part of the photoconductor from the corona.
The low residue adhesive makes it possible to use the device on a sensitive surface such as a photoconductor drum without having particles of toner adhering to any remnants of the adhesive. The device, therefore, need not necessarily be employed on the drum seal, but may also be employed on the photoconductor itself. To be absolutely sure that no adhesive or other impurities is left on the surface of the drum seal 74, the surface of the drum seal may be cleaned with a cleaning solution such as alcohol.
While the invention has been particularly shown and described with reference to a preferred embodiment thereof, it will be understood by those skilled in the art that various changes in form and detail may be made therein without departing from the spirit and scope of the invention. | Precisely positionable apparatus for collecting corona-generated current. A conductive sheet or coating is affixed to one side of an insulative sheet material. A low residue of nonresidue adhesive alone or carried by a tape is affixed to the other side of the insulative sheet. The sheet is then placed on a copier photoconductor or photoconductor carrier such as a drum, adhesive side to the carrier. The adhesive keeps the sheet flat against the surface at which the measurement is to be made. A shock protection line including front-to-back parallel diodes is connected between the conductive surface and ground. With the corona on, and the carrier in position, a current measuring device is connected between the conductive surface on a tab of the sheet and ground. | 8 |
TECHNICAL FIELD
[0001] This invention is directed to ink sets for printing a range of color intensities and hues, along with black parts, as is for the employed inkjet printing of digital, color photographs.
BACKGROUND OF THE INVENTION
[0002] With the increased emphasis on the generation of photographic images using inkjet technology, a strong focus has recently been placed on specific printing systems for photo printing. To this end, several inkjet manufacturers have introduced printers capable of printing using six, seven, or as many as eight colors to generate photo-realistic inkjet prints that exhibit excellent print quality and permanence (archivability).
[0003] This has typically been accomplished by adding one or more photo cartridges containing dilute cyan and magenta, and, optionally, black inks to the existing cyan, magenta, and yellow (CMY) ink set. Each cartridge is based either on dye-based ink technology or on pigment-based ink technology.
[0004] Typically, where dye inks and pigment inks are used together in an ink set, incompatibility of the two inks is ignored or considered desirable. Usually the dye inks and the pigment inks are in separate cartridges. When the inks are incompatible they will not flow together, and prevention of such flowing together, often termed bleed, is desirable in printing operations using standard inks. When a pigment ink is incompatible with another ink, the pigment is destabilized and settles from the liquid of the ink, which avoids bleed.
[0005] Pigmented black ink, used primarily on plain paper, is superior to dye-based black inks for some applications. The insolubility of pigment such as conventional carbon black renders the pigment less likely to migrate once it is printed on paper. This quality provides enhanced water resistance on plain paper and allows the generation of text and graphics with enhanced edge acuity over dye-based black inks.
[0006] Dye based color inks, on the other hand, typically exhibit much brighter color and higher resistance to smearing than pigment-based counterparts. As a result, they are often preferred in some applications.
[0007] Depending on the application, these divergent attributes must often be compromised because of the requirement that a particular printhead contain only pigment-based inks or dye-based inks to avoid incompatibility between the two inks.
[0008] This invention provides an ink set in which a full range of colors can be printed while two dye-based colors and pigment black are in a single printhead.
DISCLOSURE OF THE INVENTION
[0009] This invention employs the combination of two dilute dye-based inks, such as dilute cyan and magenta inks, with polymer-dispersed pigmented black ink in the same printhead. It can also be applied to other ink combinations. Specifically, a printhead containing four inks, namely dye-based CMY with pigmented black ink, would also fall under the scope of this invention.
[0010] The printhead of this invention is to be used along with full intensity inks, such as CMY inks, in one or more separate printheads. This permits full color printing of images, specifically digital photographs. The resulting image has the strong color effects of dye colorants and the pleasing dark effects of pigment black with good image definition.
[0011] Broadly, this invention is an ink set of at least two, dilute (low intensity) dye-based inks and dispersed pigment black ink. Additionally, this invention is such an ink set contained in separate compartments in a single ink jet printhead, all inks in that printhead being compatible with the black ink. This invention also encompasses a dye set of full intensity color inks separated from a printhead having at least two dilute dye-based inks and dispersantdispersed pigment ink.
[0012] Dilute inks in accordance with this invention typically have an optical density of 60% or less of the optical density of corresponding full strength ink (corresponding inks are inks of similar or identical color (hue)). Typical dilute inks have a dye content as essential colorant of 0.6 percent or less of the weight of the ink. Pigments in accordance with this invention are typically standard carbon black, with the dispersant being a polymer which may take variety of forms. Self dispersed carbon blacks are known. These can add to overall density and the pigment ink in accordance with this invention may well be a mixture of self-dispersed carbon black and polymer-dispersed carbon black.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] This invention will be described using the accompanying drawings, in which
[0014] FIG. 1 is a top, perspective view with cover omitted of a printhead illustrative of that referred which might contain the inks of this invention, and
[0015] FIG. 2 is a bottom, perspective view of the printhead of FIG. 1 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0016] This invention describes the simultaneous use of dye-based inks and pigment-based inks in the same printhead. The benefits of this technology are substantial. Foremost among the advantages of this system is the ability to produce optimized prints on a variety of media without the necessity of purchasing special printheads for divergent applications. Additionally, this technology eliminates the requirement that the consumer physically change the printheads in order to achieve optimum results.
[0017] In order to accomplish this marriage of pigment and dye in the same printhead, it is necessary to control the formulations of all of the inks. To this end, several characteristics of the inks have been identified that are necessary for proper function in this system. The main concern resulting from the interaction of the dye-based inks with the pigment-based inks is the destabilization of the pigment dispersion by components in the dye-based ink.
[0018] While the dye molecules in the inks may cause some problems, other components in the system are more problematic. Often, multi-valent salts of magnesium or other metals are added to the dye-based inks in order to improve print quality by preventing bleed. To ensure that the function of the pigmented ink is not impaired, it is necessary to optimize the dye-based inks without the use of these salts. On the other hand, pigmented inks are often formulated with the addition of latex binders in order to improve smear resistance. These dispersions are also susceptible to destabilization by the dye-based ink, and should be avoided in order to ensure proper function of all of the inks jetting from the printhead.
[0019] Black inks generally consistent with this invention are described in U.S. Pat. No. 6,646,024 B2, assigned to the assignee of this invention. One ink is a mixture of polymer dispersed carbon black and self-dispersed carbon black, and such a mixture is an ink consistent with this invention. Dispersants consistent with this invention are described in U.S. Pat. No. 6,652,634, assigned to the assignee of this invention.
[0020] The following tables detail specific examples of inks illustrative of this invention. The following abbreviations are used in the tables:
[0021] ProJet Cyan 1—A commercially sold cyan dye, the dye colorant being Direct Blue 199 in an aqueous solution.
[0022] Magenta dye—The following describes representative magenta dyes.
[0023] Wherein M1 comprises Cu, Ni, Fe, or Cr, and M comprises —H, —Na, —Li, —K, or an optionally substituted ammonium ion.
[0024] Hampene Na3T—A commercially sold trisodium ethylenediaminetetracetic acid (alternative known as trisodium EDTA), a chelating agent.
[0025] Proxel GXL—A commercially sold biocide commonly used in inkjet inks.
[0026] TEA—Triethanolamine, a buffer.
[0027] BES—A commercially sold N,N-bis(2-hydroxyethyl)tuarine or N,N-bis(2-hydroxyethyl)-2-aminoethane sulfuric acid, a buffer.
[0028] SILWET 7600—A commercially sold carbon, linear methyl mutiethyloxpropyl siloxane, a surfactant.
[0029] 2-P—2-pyrrolidone, a cosolvent.
[0030] TMP—Trimethyolpropane, a cosolvent.
[0031] EG4—Tetraethylene glycol, a cosolvent.
[0032] PEG400—Polyethylene glycol, 400 weight average molecular weight, a cosolvent.
Ink Formula 1 Dilute Cyan Dye By Weight Percent DI Water Balance ProJet Cyan 1 0.44% Hampene Na3T 0.10% Proxel GXL 0.15% TEA 0.25% BES 0.20% 1,2-Hexanediol 3.00% SILWET 7600 0.50% 2-P 6.25% TMP 6.25% 1,5-Pentanediol 6.25%
[0033]
Ink Formula 2
Dilute Magenta Dye
By Weight Percent
DI Water
Balance
Magenta Dye
0.55%
Hampene Na3T
0.10%
Proxel GXL
0.05%
1,2-Hexanediol
4.00%
SILWET 7600
0.50%
2-P
8.00%
EG4
6.00%
Tri-Propylene Glycol
6.00%
[0034]
Ink Formula 3
Representative Pigment Black
Formulation:
% by Weight
Self Dispersant Carbon Black
2.17
Dispersant Dispersed Carbon Black
1.08
PEG400
9.0
2P
9.0
1,2 Hexanediol
2.6
Hexylcarbitol
0.40%
DI Water
Balance
[0035]
Ink Formula 4
Representative Full Intensity Dye
FORMULATION
% BY WEIGHT
DI Water
Balance
ProJet Cyan 1
3.0
Dissolvine Na3T
0.10
Trimethylolpropane
6.25
2-Pyrrolidone
6.25
1,5-Pentanediol
6.25
1,2-Hexanediol
3.00
Proxel GXL
0.15
TEA
0.25
BES
0.20
SILWET L-7600
0.50
Magnesium Nitrate Hexahydrate
0.30
Sodium Hydroxide to pH 7.5, OR
0.00 to 0.10
Glacial Acetic Acid down to pH 8.2
0.00 to 0.10
[0036] Ink Formulas 1, 2 and 3 represent the two dilute, low intensity inks and the black ink of this invention. These low intensity inks are compatible with the black ink. Typically, the black ink will be somewhat diluted in intensity, but it may be full intensity. Other dilute color inks may also be included.
[0037] Ink Formula 4 represents the full intensity ink pertinent to this invention. Other full intensity inks pertinent to this invention would have magenta dye, yellow dye and may have other colorants. No novelty for the full intensity inks per se is necessary with respect to this invention.
[0038] FIGS. 1 and 2 are based on illustrations of U.S. Pat. No. 5,926,195, assigned to the assignee of this invention. The cartridge shown is illustrative of a printhead with which this invention may be employed. As shown in FIG. 1 the printhead 1 has three chambers 3 , 5 , and 7 in which two dilute color inks and one pigment black ink care kept. Similarly, in a separate cartridge the three chambers 3 , 5 , and 7 each contain full intensity inks of different colors. Orifices 9 , 11 , and 13 shown in FIG. 2 permit the ink in each chamber to leave the chamber for printing. Each orifice 9 , 11 , and 13 is in separate liquid communication with one of the chambers 3 , 5 , and 7 . As is widely practiced, the printhead 1 has a thermal chip or other ink discharge device (not shown) which receives ink from orifices 9 , 11 , and 13 and applies to ink in small dots or pels on the media being imaged.
[0039] Ink exits the printhead 1 from the same side (the side having orifices 9 , 11 , and 13 in FIG. 2 ) and generally from locations close together. Moreover, during non-use the printhead is brought to a location at which the exit ports are capped to prevent evaporation of the ink. Accordingly, inks in the typical printheads are subject to some moderate transfer of ink between chambers, such as chambers 3 , 5 , and 7 . In accordance with this invention, the dilute inks must be compatible with the black inks in the moderate amounts which can be transferred across the printhead.
[0040] Experimental data shows stability of the foregoing mixtures of dilute dye-based inks and the pigment-based ink. Two inks, one black, were mixed at various ratios and stored at 60° C. for 24 hours. The particle size of the resulting liquid was then measured. Any observed increase in particle size in this experiment indicates instability. The presence of salt (Mg(NO 3 ) 2 ) in a cyan ink leads to much greater particle size growth in this test.
[0041] A second experiment measures the impact of the contamination of pigmented black ink with dye-based cyan ink in the same printhead. After subjecting the cartridges to severe printing conditions, the number of missing black nozzles was measured. For this experiment, polymer-dispersed pigmented black ink formulated without the addition of latex binder was employed. The same levels of salt (Mg(NO 3 ) 2 ) were employed in these cyan inks as in the particle-size test. The presence of salt in the cyan ink causes a substantial increase in the number of black nozzles that are missing after severe printing. | Ink sets comprising, for example, dilute cyan dye-based ink, magenta dye-based ink and black ink of carbon black dispersed by a polymeric dispersant. The dye inks are formulated to not destabilize the black ink. A broader ink set is the forgoing inks in combination with full intensity cyan, magenta and yellow inks used to print full color photographs. The dilute ink and the black ink are in the same printhead. | 2 |
[0001] This application claims the benefit of U.S. Provisional Patent Application No. 61/126,554 filed Apr. 29, 2008.
FIELD OF THE INVENTION
[0002] The invention relates to trash receptacles.
BACKGROUND OF THE INVENTION
[0003] The amount and collection of trash is an ever-growing problem. This is especially true in consumer sectors where a large amount of refuse is discarded daily. Most consumers have trash receptacles adjacent to their homes for collecting trash generated in or around the home. The contents of the trash bins may be collected or disposed of on a regular basis, for example by curb side pickup.
[0004] When people are outdoors they may not take the time to take their trash to a garbage receptacle inconveniently located a long distance from the trash origination location. Consequently, this presents problems people who are enjoying the great outdoors. Therefore, the trash may be left on the lawn, in the streets, and in the sewer drainage thereby polluting the environment.
[0005] The inventor recognized that it would be advantageous to have a trash container for storing paper, bottles, glass cans, and other trash, that is mountable to an upward extending structure.
[0006] The inventor recognized that it would be advantageous to have a trash receptacle that can be secured outdoors to fixtures including horizontal or vertical application, such as, railings, horizontal posts, terraces, porches, gates, decks, or balconies. The inventor recognized that it would be advantageous to have a trash receptacle that is configured to be mounted with removable straps or another suitable hanger for secured placement.
[0007] The inventor recognized that it would be advantageous to have a trash receptacle that can be secured to flat wall surfaces including brick, siding, drywall or wood to increase the usability in indoor or outdoor locations. The trash receptacle is also configured to be attached to a wall mount for flat surface mounting. The increased usability may be obtained by mounting the receptacle in a position raised above the floor or ground so as to free said floor or ground for alternative uses.
SUMMARY OF THE INVENTION
[0008] The trash collection device of the invention provides has a body for containing trash, a cover hingeable to the body. The body has an opening for receiving a connector that is connectable to an external structure.
[0009] In an embodiment, the body comprises a flat surface for mounting against an external structure.
[0010] In an embodiment, the opening comprises two opening each for receiving a connector that is connectable to an external structure.
[0011] In an embodiment, the body has a base and an upper portion. The upper portion extends under the base to support the base.
[0012] In an embodiment, the base and the upper portion of the base are each integrally molded components.
[0013] In an embodiment, the cover has a handle, and the body had a latch. The handle is releasably engagable with a latch for securing the cover over the body in a closed condition. The handle may have a push button release for engaging and releasing the latch.
[0014] In an embodiment, the body has a hinge mount. The hinge mount has at least one spring element for biasing the cover towards an open position.
[0015] In an embodiment, the device has a mount plate connectable to the body for attaching the device to an external surface. The mount plate is connected to the body by at least one spacing connector, where the spacing connector separates the body from the from the mount plate.
[0016] In an embodiment, the spacing connector has end portions, and the mount plate has engaging receivers, the end portions are sildably engageable with engaging receivers to connect the spacing connector to the mount plate.
[0017] In an embodiment, the spacing connector has end portions, and the body has engaging receivers. The end portions are sildably engageable with engage receivers to connect the spacing connector to the body.
[0018] In an embodiment, the body has a back with vertically extending impression areas, and wherein the opening is located in a top portion of the impression areas.
[0019] An advantage of trash collection device is that it enables users to mount a trash receptacle in very convenient places such as outside of one's residence or corporate buildings. Another advantage of the trash collection device is that it enables a user to open a trash cover with ease by the push of a button.
[0020] Another advantage of trash collection device is that the device can be left in place and emptied by lifting a plastic liner out of the trash container.
[0021] Another advantage of trash container is that it can be installed on flat wall surfaces such as brick, siding, drywall, wood, etc. for additional space saving benefits indoors or outdoors. The space saving benefits are realized because the container may be suspended above the floor or ground, and therefore frees the floor or ground space for other uses.
[0022] Yet another advantage of trash collection device is that it can be installed on fencing, railings, decks, etc without modifying the trash container or an external support structure, such as a fence railing. Trash collection device can be used to store bulk materials in outdoor or indoor locations.
[0023] Numerous other advantages and features of the present invention will become readily apparent from the following detailed description of the invention and the embodiments thereof, and from the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] FIG. 1 is a front perspective view of a trash collection device or container of the invention;
[0025] FIG. 2 is a second front perspective of a the container with a cover removed;
[0026] FIG. 3 is a back view of the container with the cover removed;
[0027] FIG. 4 is a top view of the container with the cover removed;
[0028] FIG. 5 is perspective view of the cover;
[0029] FIG. 6 is a third perspective view of the container;
[0030] FIG. 7 is a rear perspective view of the container;
[0031] FIG. 8 is an enlarged fragmentary view taken of the mount;
[0032] FIG. 9 is a second rear perspective view of the container; and
[0033] FIG. 10 is a third rear perspective view of the container attached to an exterior structure.
DETAILED DESCRIPTION
[0034] While this invention is susceptible of embodiment in many different forms, there are shown in the drawings, and will be described herein in detail, specific embodiments thereof with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the invention to the specific embodiments illustrated. U.S. Provisional Patent Application No. 61/126,554 is incorporated by reference.
[0035] FIG. 1 shows the portable trash collection device or container 100 in a closed condition. Container 100 may have a semi round shape across a front wall of the container 100 as shown in FIG. 2 . The container 100 includes a body 110 having a semi round cavity with a hinged cover 130 and a reinforced bottom floor 140 . The body 110 fits over the folded sections of bottom floor 140 as shown in FIG. 4 to reinforce the bottom of the container 100 . The bottom 140 has holes for draining liquids that may accumulate in the container 100 . In another embodiment the bottom and the body maybe made as one unitary part.
[0036] The cover 130 has a handle 132 . The handle connects and secures to a latch 134 of the body 110 . The latch 134 is releaseably engagable with the handle 132 . The handle 132 may comprise a push button release whereby the latch is released when the handle is pushed downward.
[0037] As shown in FIG. 2 , the body contains a hinge section that is integral with the top of back wall. Cover has a front lip with push button. The back as shown in FIG. 3 has a pair of horizontal directed slots. As shown in FIG. 6 , tabs fit upwardly through slits so that back section can hold the cover in position.
[0038] FIGS. 2 , 3 , 4 , 9 , and 7 , show a back 114 of the container 100 has a pair of vertical impression areas 118 a, 118 b that extend from the bottom of the body 110 . The back may be generally flat in shape. The vertical impressions have ends 118 c, 118 d on the back 114 below the top perimeter 112 . The ends 118 c, 118 d extend from the inner portion of the impressions toward the outer portions of the back 114 creating a substantially horizontal surface. The ends 118 c, 118 d each have retaining exit strap holes 116 c, 116 d respectively. The back has two hinge mounts 120 , 122 . The hinge mounts 120 , 122 each have entry strap holes 116 a, 116 b, respectively. The exit strap holes 116 c, 116 d, correspond to the entry strap holes 116 a, 116 b, respectively. It is understood that the exit strap holes and entry strap holes could be swapped in their function so that the exit strap holes operate as entry strap holes and the entry strap holes operate as exit strap holes. The entry holes receive the straps which extent out the exit holes. As shown in FIG. 10 , straps 150 , 152 may be used to secure the container 100 to an exterior structure, such as a fence 1010 , a wall or another upward extending structure. The mount may supportably connect the device to an upwardly extending structure so as to suspend the device above the ground or an underlying surface.
[0039] FIG. 4 . shows the hinge mounts 120 , 122 . The hinge mounts 120 , 122 each have a support 144 , 146 . The hinge mounts have pivot bars 140 , 142 . Pivot connectors are formed in the hinge mount extensions 137 , 138 pivot of the top 130 . The pivot connectors are c-shapped and engagable with the pivot bars 140 , 142 . The pivot connectors have a spring engagement element. The spring engagement elements engage springs 148 , 149 of the hinge mounts 120 , 122 . The springs bias the cover 130 towards an open condition, as shown in FIGS. 6 , 7 , 9 , and 10 when engaging the spring engagement elements. When the latch 134 is released, the springs bias the cover towards an open condition to provide access to the interior of the container.
[0040] FIGS. 7 and 8 show a container 100 having a mount 160 . The back 114 is connected to the wall mount 160 by support connectors 162 and 164 . The wall mount 160 has a wall side 160 a and a container side 160 b. The support connectors 162 , 164 slidably engage the support connector engagement members 124 , 126 . The support connectors 162 , 164 engage receivers 168 , 169 , respectively of the mount 160 . FIG. 8 shows one of the support connector 162 and the mount 160 in detail. The support connectors 162 and 164 are identical. A wall engagement end 162 b of the support connectors slidably engages the support connector engagement member 168 . The engagement member 168 has a bottom stop 168 a that prevents the support connector 162 from exiting the engagement member 168 in the A direction. The mount engagement end 162 b engages the receiver 124 wall 114 . The mount 160 has a number of holes 167 a, 167 b, 167 c for securing the mount 160 to an external surface. The mount is attachable to an exterior structure, such as a wall, so as to support the device 100 .
[0041] As shown in FIG. 10 , a bag 1002 can be inserted into the cavity of the body 110 and the open end of the bag is folded over the top perimeter 112 of the body 110 . The bag 1002 may be held in place when part of the open end of the bag 1102 is slid between the body member 110 and the cover 130 when the cover is in a closed condition. The bag 1002 may also be held in place by securing the bag around the outside of the top perimeter 112 with a tightening string or strap (not shown). This holds the upper portion of bag in a tight relationship relative to the top of container. Cover 130 closes on top of the open bag.
[0042] The container 100 may be made of corrugated plastic, aluminum, steel, or another durable material. The surfaces of the container may be coated with material that resists water, snow, ice and the like. Printed matter and color can be applied to the container. While the container may be useable with other items, it is particularly configured for containing trash and recycling items.
[0043] From the foregoing, it will be observed that numerous variations and modifications may be effected without departing from the spirit and scope of the invention. It is to be understood that no limitation with respect to the specific apparatus illustrated herein is intended or should be inferred. | A trash collection device having a body for containing trash, a cover hingeable to the body. The body has an opening for receiving a connector that is connectable to an external structure. The body has a flat surface for mounting against an external structure. | 1 |
FIELD OF THE INVENTION
This invention relates to an object detector and finds particular application in the field of vehicle detection where a detector loop is laid in the roadway or other place where vehicle detection is required.
BACKGROUND OF THE INVENTION
More particularly the invention is concerned with a locked oscillator type of detector in which the detector loop is made a frequency determining element of a first oscillator and which comprises a second internal oscillator which is coupled to the first and its frequency adjusted such that by virtue of the mutual coupling the oscillator frequencies lock together. A detector of this type is disclosed in British Patent Specification No. 1,338,062 of Wilcox. When a vehicle influences the detector loop oscillator the frequencies of the two oscillators remain locked but there is a shift of their relative phase which is detected and processed to provide an indication of the presence of a vehicle.
In known locked oscillator detectors, the detector loop is made an element of a conventional tuned circuit for the first or loop oscillator and the internal oscillator has to be adjusted in frequency until the oscillators lock at or near the natural frequency of the loop oscillator. The natural frequency can vary widely depending on the loop requirements of each installation and the internal oscillator has to be manually tuned in each case.
SUMMARY OF THE INVENTION
It is therefore generally desirable to provide for automatic tuning of the internal oscillator, thereby avoiding the need for manual setting and without needing to know the natural frequency of the loop oscillator. It is then necessary to ensure the lock frequency acquired is held. There will be described hereinafter an embodiment of the invention which achieves these aims.
In one aspect the present invention is applied to an object detector comprising a first oscillator having an inductive object sensing loop as a frequency determining element therefor, and a second tunable oscillator and means for coupling energy from the second to the first oscillator whereby the first oscillator may be locked to the second upon tuning of the second oscillator; a phase detector responsive to the first and second oscillator signals to provide a signal representing the phase difference therebetween when the oscillators are locked; and signal processing means responsive to said phase difference signal to provide an object indicative signal. The invention proposes the improvement wherein said second oscillator is made the controlled oscillator of a phase locked loop (PLL) having a reference frequency source; and wherein there is provided first means to sweep said second oscillator from one end of a frequency range while disabling the normal operation of the phase lock loop; and second means to detect the locking of the first oscillator to the second and activate said first means to enable the normal operation of the phase lock loop to lock the second oscillator, and therewith the first, with respect to the reference frequency at a frequency at or closely adjacent to that at which locking of the first to the second oscillator was detected.
According to another aspect of the invention there is provided an object detector including a first oscillator having an object-sensitive inductive loop as a frequency determining element therefor; a phase lock loop (PLL) including a voltage controlled oscillator (VCO) and a reference frequency source to which the VCO frequency is lockable; means coupling the VCO to the first oscillator to inject the VCO signal into the first oscillator for locking the first oscillator frequency to that of the VCO; means responsive to the first oscillator and VCO signals to provide a signal indicative of the locking condition; control means connected to the PLL and settable into a first state disabling normal operation of the PLL and into a second state enabling normal operation of the PLL; means activated by said control means being set into its first state to cause said VCO to sweep over a frequency range; and said control means being responsive to said locking indicative signal to be set into its second state.
The invention and its practice will be further described with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram illustrating a prior locked oscillator vehicle detector;
FIG. 2 is a circuit diagram partly in blocked diagram form, partly schematic, illustrating a locked oscillator vehicle detector embodying the present invention;
FIG. 3 shows a set of time waveforms relating to the operation of the phase lock loop 110 in FIG. 2; and
FIG. 4 shows the pin connection diagrams of two integrated circuit devices used in the phase lock loop.
THE PRIOR ART
Referring to FIG. 1, the figure shows the essential circuit blocks of a locked oscillator vehicle detector such as described in the aforementioned Wilcox specification No. 1,338,062.
The detector comprises a road loop oscillator 10 whose inductive vehicle detecting loop 12 laid in the roadway is made a frequency determining element of a resonant tank circuit of say a Colpitts' oscillator (not shown in detail). The detector also has an internal oscillator 14 with, in this case, a manually tunable inductor L also forming part of the resonant tank circuit of a Colpitts' oscillator. The oscillator outputs are applied to a phase detector 16 which may, in accord with specification No. 1,338,062, be based on a transistor to the base and emitter of which the respective oscillator signals are applied and at the collector of which is developed an output signal dependent on the phase relationship of the oscillator signals. The phase-dependent output signal is applied to a processing circuit 18 which analyses phase changes to determine the presence of a vehicle at the road loop 12 and which may contain what are known as tracking facilities, all as described in specification No. 1,338,062.
To give the required phase dependent response the two oscillators are locked in frequency through a mutual coupling element R c . Ignoring the unit in dashed line, energy transfer is bidirectional and the oscillators achieve a mutually-dependent lock frequency as the frequency of internal oscillator 14 is tuned to approach that of the loop oscillator 10. A vehicle presence at the loop 12 tends to increase the loop oscillator frequency. The two oscillators remain locked in frequency but the arrival of the vehicle changes the phase relationship between the oscillators. This mutual locking technique is also shown in specification No. 1,338,062.
An improvement in operating sensitivity can be achieved by inserting a buffer amplifier 20 to follow the internal oscillator. This is known as the driven-loop technique since energy coupling is now unidirectional from oscillator 12 to oscillator 10. The loop oscillator thus locks to the internal oscillator and for a given parameter change at the loop 12 there is a greater relative phase change in this case than in the mutually-coupled case.
In both cases it is necessary to manually tune the internal oscillator 14 to the loop oscillator frequency which, depending on the loop used in a given installation, may have a natural frequency extending over a wide range, e.g. 20 to 150 kHz. The sensing of the lock condition can be done by monitoring the output voltage V p of the phase comparator which will go from say a relatively low value to a relatively high value as lock is achieved.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Turning now to the circuit of FIG. 2, this shows the application of the invention to a driven loop detector such as described above and like parts are given like reference numbers. Only so much of the detector circuit is illustrated as is necessary for an understanding of the practice of the present invention. The circuit may be divided broadly into three sections: the basic vehicle detector 100; a phase lock loop 110; and condition sensing and control circuitry 120.
The basic vehicle detector 100 comprises road loop oscillator 10, phase detector 16, coupling element R c , buffer amplifier 20 and processing circuitry 18'. The circuit includes an internal oscillator 14' but this is not directly applied to the buffer stage 20 but is used as a reference to control the frequency of a voltage controlled oscillator (VCO) 112 in the phase lock loop (PLL) 110. Thus the loop oscillator 10 is locked to the VCO. As will become apparent from the following description, manual tuning of the oscillator 14' for lock is no longer required.
A small part of the signal processing circuit 18' is shown since conveniently parts of the circuit used in the signal processing for vehicle detection may be used in other functions to be described. The circuit is only illustrated to this extent.
The condition sensing and control circuitry 120 is employed to sense a low voltage condition set out below and is responsive to it to initiate an automatic operation for tuning of the VCO to the loop oscillator frequency, and in response to sensing of a state of lock between the VCO and the loop oscillator to establish the control of and the subsequent maintenance of the locked condition. The automatic tuning phase of operation will be called the tune mode. Upon the lock being sensed the circuit enters a mode of operation which will be called the lock mode in which the VCO is itself locked through the PLL to a multiple of a reference frequency derived from oscillator 14'. The multiple need not be known: by selection of a sufficiently low reference frequency f r the PLL locks the VCO, and therewith the loop oscillator, to a frequency close to that to which the VCO was tuned to achieve lock. Thus the frequency increment in which the PLL is steppable has to be small enough to ensure a proper retention of the locking of the loop oscillator whatever the VCO frequency achieved in the tune mode.
Control of the VCO is realised by the voltage (assumed positive with respect to ground) applied on terminal 114 via a loop filter 116. The VCO may be based on the CD4046 CMOS integrated circuit and full data is available in the manufacturer's data, e.g. RCA: "COS/MOS Integrated Circuits" data book published 1978. The VCO frequency increases with increasing positive voltage on terminal 114. The major element in the loop filter is a shunt capacitor C1 which effectively acts as an integrating capacitor in the control loop, the VCO presenting a high input impedance. The capacitor is charged or discharged via terminal 118 from one of three sources to be described. It will suffice to say for the present that on entering the tune mode the VCO is swept from the high frequency end of its range until lock is sensed. This requires placing a high initial voltage on the capacitor and then discharging the capacitor.
The tune mode is entered when power is first applied to the circuit or when the circuit supply voltage drops below a set value, or when a deliberate reset is applied to the circuit. The circuit contains a power supply unit (PSU) 122 which supplies an unregulated voltage +V' and a regulated voltage +V. The unregulated voltage is sensed by a unit 124 which can take many forms, e.g. using a zener diode as a reference. Upon switch on of the PSU 122 the voltage supplied takes a short while to build up. While it is below a value set by the zener reference, or if later the voltage +V' falls below that value, a transistor TR1 is turned fully on to discharge or hold discharged a capacitor C2 which is chargeable from the regulated voltage rail +V through resistor R1 and through the base-emitter circuit of a transistor TR2 in parallel with resistor R3. The collector of transistor TR2 is grounded through resistor R4. As long as transistor TR1 is on, the junction of R1 and C2 is low and supplies a first control signal on line 126; also, transistor TR2 is turned on and its collector voltage is high. This is supplied as a second control signal on line 128. When the voltage sensed by unit 124 rises above the set value, transistor TR1 is turned off allowing capacitor C2 to charge with the time constant R1.C2 to essentially +V so that the control signal on line 126 goes high. As C2 charges the transistor TR2 turns off so that its collector and line 128 go to ground potential (i.e. low). Even a momentary interruption in the supply voltage V' will cause TR1 to turn on and discharge capacitor C2 and time constant R1.C2 ensures lines 126 and 128 go low and high respectively to put the circuit into the tune mode as the PSU voltage rise. This low voltage sensing condition can be also manually induced in unit 124 by closing a reset switch SW1.
The control signal on line 126 is applied to a bistable device 130 which acts as a memory of whether the circuit is in the tune or lock mode and itself generates certain control signals. The bistable device can be realised in many ways. As shown it is a pair of coupled inverters 132, 134 having an input point 136 to which is connected a pair of input diodes D1 and D2. The diode D1 is poled to pass a low on line 126 to point 136 forcing the output of inverter 132 high and of inverter 134 low which state indicates the tune mode and is retained until point 136 is taken high. This cannot be done when line 126 goes high again because of the isolation afforded by diode D1. Thus the low on line 126 indicating entry into the tune mode is memorized by bistable device 130.
At the same time the high on line 128 is applied to the control gate g of a switch SW2 connected between the supply rail +V and the filter capacitor terminal 118. The high level closes the switch to charge capacitor C1 to +V and set the VCO frequency at the upper end of its range. As line 128 goes low again the switch is opened. The switch SW2 (like the switches SW3 and SW4 to be mentioned) is an electronic bilateral switch such as found in the CD4016 CMOS device which contains four such switches. The switch is closed or open dependent on its gate voltage being above or below a certain value.
Having put full voltage on the capacitor C1 it is now discharged by a constant current source 138 which since it is discharging current to ground acts as a sink. The value of the current I 1 is proportional to the value of an input current to the circuit 138 at terminal 140. The input current at this time is set by the value of a resistor R4 connected to the +V rail. It will be seen that the constant current sink is continuously active via resistor R4. The sink current here is relatively low and does not, of course, affect the charging of capacitor C1 through switch SW2. The capacitor C1 thus discharges to sweep the VCO frequency downwards towards the lock condition at a relatively slow rate.
Attention will now be given to the detection of the lock condition. For this purpose the condition of the output voltage V p of the phase detector 16 is monitored. In the lock condition the voltage V p will lie in the region of a certain voltage level--the precise value depends on the phase relationship--and this level is distinct from the level obtained when the loop oscillator and VCO frequencies are different.
In the illustrated case the voltage V p is applied to a transistor TR3 that is the input stage of the signal processing unit 18' and feeds other circuitry that is here simply represented as an inverter amplifier 142. The circuit elements would be part of more complex analysis and tracking circuitry not relevant to the present discussion save to note that where tracking circuitry is used it is not essential to achieve a precise phase relationship in the lock condition since the tracking circuitry will adapt to it within limits. This is of advantage as will become clearer below.
The lock detection is carried out by clamping the emitter of transistor TR3 to a reference voltage +V R applied by a switch SW3 of the same kind as switch SW2. Voltage V R is obtained from a zener diode and its value is selected with regards to the expected lock level of V p . While V p is low (no lock) transistor TR3 is conducting and the output of amplifier 142 is low. The amplifier is connected through the diode D2 to the input point 136 of the memory bistable 130 currently in the tune mode state. As lock is reached, voltage V p rises--the transistion is abrupt--to cut off transistor TR3 and cause the output of amplifier 142 to go high. Diode D2 is poled to pass the high level to point 136 which in turn switches the bistable device 130 to its other or "lock mode" state. As the output of inverter 132 goes low switch SW3 is opened to allow transistor TR3 to revert to its normal signal processing role. Changes in the output of amplifier 142 during normal signal processing will not affect the bistable device which can only revert to the tune mode state by means of low level applied through diode D1. In the lock mode the output of inverter 134 is high and closes a further electronic switch SW4 that connects the input terminal 140 of current sink 138 to one output of a digital comparator 144 through a resistor R5 in readiness to now lock the VCO frequency, and therewith the loop oscillator frequency, to a multiple of a reference frequency.
Looking now at the PLL 110 in more detail, it is seen that the VCO output is connected directly to one input of phase comparator 144. The VCO frequency will be denoted f v . The output of reference oscillator 14' at frequency f r is divided in frequency by a multi-stage binary divider 146 (e.g. a CD 4024 device) and the divided output frequency f r is applied as the reference frequency input to comparator 144.
The value of f r determines the frequency increments in which the VCO may be finally locked. As will be shown later the action of the digital phase comparator in the PLL allows f v to be locked to a multiple of f r over a wide range of multiple. The increment f r should be small enough such that upon locking the VCO in the PLL after indicating lock between the loop oscillator and the VCO, the consequent frequency shift in the VCO and loop oscillator does not take the processing circuit 18' out of the phase limits to which it can adapt. While f r can be made as small as desired, a typical value is about 200 Hz. If divider 146 uses seven binary stages (divide-by-128) then the reference oscillator 14' operates at about 25 kHz. This is convenient. It is of the same order as the frequency of loop oscillator 10. The reference oscillator remains a Colpitts oscillator using a similar circuit to that of the loop oscillator 10. In this way the reference oscillator can be given temperature drift characteristics akin to those of the loop oscillator and thus provide some degree of temperature compensation.
The comparator 144 has two outputs 148 and 150, the former being connected to switch SW4 as already mentioned and the latter being connected to the input 152 of source 154 whose output is connected to filter capacitor terminal 118. The source 154 is complementary to sink 138 producing a current I 2 to charge the capacitor C1 that is in direct proportion to the current in an input resistor R6. By alternately charging and discharging the capacitor by means of the current source and sink under the control of phase comparator 144, the VCO frequency f v is locked as a multiple of the reference frequency f r as will be further described with reference to FIG. 3.
The digital phase comparator 144 comprises a pair of D-type flip-flops 156 and 158, e.g. device 144 may be a type CD4013, that are clocked by the respective frequency signals f r and f v and are cross-connected to provide output signals in a manner that will be described with reference to FIG. 3. For convenience, the two flip-flops 156 and 158 will be called A and B and their conventionally notated terminals suffixed correspondingly to distinguish them. It will be noted that the D input of the reference frequency flip-flop A is taken to the second input of the memory bistable that is low in the tune mode. Consequently flip-flop A is continually clocked high at output Q A so that the source 154 is not activated using the device specified below. Q A holds D B low so that flip-flop B is also clocked low at Q B in response to the frequency signal f v . No change can take place in the comparator until terminal D A goes high when the comparator responds to the next leading edge of a clock pulse f r . Terminal D A goes high when the memory bistable 130 changes state from the tune mode to the lock mode.
FIG. 3 shows a set of time waveforms for f v , f r , Q A , Q B , and V c the filter capacitor voltage at terminal 118. With D A high, at t 1 Q A is clocked high at a leading edge (positive-going) of f r . With D B high the next following leading edge of waveform f v at t 2 clocks Q B high to reset Q A low whereupon Q B is clocked low at the next leading edge of f r at t 3 . It will be seen that Q B is high to drive an input current through resistor R5 to activate sink 138 for a full period (t 3 -t 2 ) of f v while Q A is low to activate current source 154 through resistor R6 for the interval (t 2 -t 1 ) which is less than a full period of f v .
The resultant capacitor voltage is seen at V c where the capacitor C1 is charged from t 1 to t 2 , discharged from t 2 to t 3 and then continues very slowly discharging due to the continuously active sink input resistor R4 over the remaining portion t 3 to t 4 of the period of the reference frequency f r . The operational cycle repeats at the next leading edge of f r . The variations of V c shown are at some mean level of V c which is related to the value of the multiple f v /f r . It will be seen that the procedure illustrated in FIG. 3 can occur over a wide range of multiples, the interval (or phase difference) (t 2 -t 1 ) adjusting itself to obtain a stable cycle in each case. The exact multiple of f r at which the PLL operates is not of importance. The finally locked frequency f v will lie near that at which initial lock of the VCO with the loop oscillator was signalled. Thus the circuit is able to tune and operate automatically at a stable frequency locked to f r anywhere within the VCO range.
Referring again to FIG. 3, it will be clear from the waveform V c that resistor R5 is of much smaller value than resistor R4 assuming approximately the same input voltage applied to each and the current in R5 is the predominant controlling factor during the interval (t 3 -t 2 ). For example, for a capacitor C1 of 4.7 μF, R4 may be 1MΩ and R5 56 kΩ.
When the PLL is settled it will be seen that for the V c cycle to remain in equilibrium the time integrals of the capacitor charging and discharging currents are equal. Because at equilibrium t 2 -t 1 is less than t 3 -t 2 , resistor R6 needs to be made smaller than R5, assuming an equal applied voltage and equal source and sink proportionality ratio, and to be made somewhat smaller still to allow for the discharge during the interval (t 4 -t 3 ). For the values of R4 and R5 given above a suitable value for R6 is 15 k.
The constant current source and sink may be realised in various ways. One convenient arrangement is to use for each the two complementary pairs of a CD4007 CMOS device (or CA 3600). Each device also contains an inverter and the two inverters are conveniently used to form the bistable memory 130. The pin connections of a CD4007 to form a constant current sink and source are shown in FIG. 4 at the bottom and top respectively. The unused pins 9-12 are those of the inverter. Further details are available in the data book referred to above. In the case of sink 138 of FIG. 2 the control input 140 needs to be taken high for the specified sink of FIG. 4 to operate. In the case of source 154 as exemplified in FIG. 4, the input 152 needs to be taken low to activate the source.
It will be appreciated that while the lock detector circuitry TR3, 142 has been described as part of the signal processing circuit 18' it can be made separately for this specific purpose. | A vehicle detector installation includes a loop oscillator the loop of which is laid in the roadway and which is locked in operation to a voltage controlled oscillator (VCO). Vehicle detection is effected by a phase detector monitoring the phase difference between the oscillators. The VCO is incorporated in a phase-lock loop (PLL) that is capable of locking to a multiple of a reference frequency oscillator over a range of multiples. To achieve the locking of the loop oscillator to the VCO, means are provided for disabling the normal operation of the PLL and sweeping the VCO over its range of frequency until the phase detector indicates that the loop oscillator and VCO frequencies are equal. This indication activates the PLL to its normal operation to pull the VCO and therewith the loop oscillator to an adjacent multiple of the reference frequency. The PLL is maintained by a repeated charge/discharge cycle of the VCO capacitor that is dependent on the phase of the reference oscillator and the VCO. | 6 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application discloses and claims subject matter which was disclosed in copending provisional patent application Ser. No. 60/552,820, filed Mar. 12, 2004.
FIELD OF THE INVENTION
[0002] This invention relates to a system for resurfacing ice skating rinks.
BACKGROUND OF THE INVENTION
[0003] Ice skating is extremely popular in the northern states of America and is growing increasingly popular in the southern states. The demands for ice skating surfaces are becoming nearly impossible to meet. Many ice rinks have to operate 24 hours a day to meet skaters' needs. The number and availability of ice skating rinks are limited by the maintenance required to keep the quality of the ice surface in an optimum or at least satisfactory condition. Such maintenance involves eliminating ruts and the like created by the skaters, removing the resulting ice particles, removing any fallen snow accumulation (in the case of an outdoor rink), and controlling the thickness of the ice.
[0004] It is important to control the thickness of the ice. The average ice thickness on an indoor ice skating rink is about 0.75 to 1.0 inch. If, for example, a person were merely to constantly shovel away the ice powder created after an ice skating session and reapply water, the ice would eventually become too thick for the ice chillers to handle and the ice would become soft and wet.
[0005] Backyard or homemade ice rinks, ponds, and lakes are called natural ice skating surfaces. They are usually created outdoors when the temperature is constantly below 25° F. Natural ice skating surfaces rely on cold air temperatures to keep the surface frozen. Even in colder climates, ice skating surfaces cannot have thick ice because they are hard to keep frozen. Natural ice skating surfaces also have the disadvantage of not having protection from snowfall.
[0006] Typically these smaller rinks are maintained manually, by one or more persons using hand tools, such as a shovel, a wheelbarrow, a hose, and a T-shaped squeegee-like implement. This not only tends to be burdensome, labor intensive, energy-depleting, and slow, but it also may produce an uneven, unduly thick, and/or poor quality surface. As a practical matter, the long term result of these deficiencies is likely to be that the ice surface is resurfaced with insufficient frequency. Manual maintenance also requires fairly large quantities of water, and sometimes creates fog which can be a problem in enclosed rinks. As a member of a neighborhood recreation association having a 7,000 sq. ft. indoor ice skating rink, I have had personal experience in hand shoveling and resurfacing and the attending disadvantages thereof. That experience led to the present invention.
[0007] Large ice resurfacing machines such as those sold under the trademark Zamboni® or Olympia® have been used for many years for large rinks, for example regulation hockey rinks having regulation dimensions of 200 ft.×85 ft. and other rinks having an area of 19,000 to 20,000 sq. ft. These large machines are excellent for large rinks, but their initial expense, size, complexity, training, maintenance, and storage requirements render them less suitable for medium and small size rinks, such as those operated by homeowners, municipalities, recreation associations, parks, private establishments, and the like. Currently such machines of one manufacturer have a selling price in the lower $70,000 range and weigh in excess of 9,000 pounds. Also, their size limits their turning radius and maneuverability and often requires a separate building for storage. In addition, they are complex, requiring considerable skilled maintenance and operator training. Certification of an operator of one of these machines requires that he or she attend a 3-day training course. More recently, downsized versions of these machines such as the Zamboni® Model 100 and the Olympia 250® have become available, but aside from their size and weight these have many of the same shortcomings.
[0008] The Zamboni® and Olympia® and various other machines shave off a surface ice layer of a sufficient depth, which can be as much as ⅛ inch, to remove substantially all of the ruts, and then deposit water on the resulting rut-free substrate so as to create an entirely new layer of fresh ice on the substrate. The shaving produces a rather large quantity of ice particles or “snow”, which is carried away by conveyors in the machine, stored in a snow box in the machine, and later disposed of as waste.
[0009] There has been a long-felt but unmet need for an ice resurfacing machine which has the following attributes and capabilities: relatively low initial cost; compact; easily maneuverable; short turning radius; easy to maintain and repair with standard parts; operator friendly; minimum water requirements; minimum snow disposal requirements; fast; adjustable; flexible, with ice thickness reduction capability and heavy snow removal capability; providing high quality ice surfaces; suitable for ice skating rinks of any size, including small and medium size rinks; and suitable for both indoor and outdoor use.
BRIEF SUMMARY OF THE INVENTION
[0010] An object of the invention is to fill the above-identified need, or at least provide as many of the attributes and capabilities as possible, bearing in mind the compromises necessary to reconcile the inherent competition between them.
[0011] Rather than remove a layer of ice that is sufficiently thick to remove substantially all of the ruts and then replace it with water, the present invention removes only a thin layer of ice, leaves the ruts, fills the ruts with snow, and adds hot water to fill the interstices in the snow in the ruts and melt that snow. This leaves the ruts completely filled with water, which when frozen will provide a smooth ice surface and effectively eliminate the ruts.
[0012] The inventive approach eliminates the need for apparatus to convey large quantities of snow off the ice and into the resurfacing machine, to store it in the machine, and to haul it away. This greatly reduces the cost, size, weight, and complexity of the machine. It also conserves water. Also, the inventive machine has the capabilities of removing heavy snow and reducing ice thickness. In addition, it is easy to operate and maintain and produces an excellent ice surface. Further, it works sufficiently fast to be useful for larger rinks as well as small and medium-size rinks.
[0013] Apparatus utilizing this approach takes advantage of and enhances these and other aspects and advantages of the invention, including an integrated combination of a light towing vehicle, a compact resurfacing attachment, and a lifting and leveling assembly connecting the vehicle and the attachment.
[0014] Sales data for ice resurfacing machines according to the present invention are consistent with my belief that the invention fills a long-felt need. My company, Ragged Point Industries, sells these machines under the trademark “The Ice Wizard”. The first sale took place on Sep. 27, 2004. In the less than 6 months since then, we have sold 22 of these ice resurfacing machines, in the United States and abroad. One of these machines is being used at the ice skating rink on the Eiffel Tower in Paris. Four of them are being used at ice rinks in Saudi Arabia, and another one is being shipped to Saudi Arabia. Ours is not a large or sophisticated operation, as all of these machines were assembled by my partner and me at my personal residence, when we were (as we still are) employed full-time in our “day jobs”.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0015] FIG. 1 is a right side elevation view of an ice resurfacing machine according to the invention, resting on an ice surface.
[0016] FIG. 2 is side section view of the resurfacing attachment shown in FIG. 1 , showing a portion of the lifting and leveling assembly.
[0017] FIG. 3 is a plan view of the resurfacing attachment shown in FIGS. 1 and 2 , with the water spreader towel removed.
[0018] FIG. 4 is a rear view of the resurfacing attachment shown in FIGS. 1-3 .
[0019] FIG. 5 is a view similar to FIG. 2 , but showing the invention being used in resurfacing ice.
[0020] FIG. 6 is a plan view of a turn groove in an ice surface.
[0021] FIG. 7 is a section taken at 7 - 7 in FIG. 6 , with the groove filled with snow.
[0022] FIG. 8 is a plan view of a slip or stop gouge in an ice surface.
[0023] FIG. 9 is a section taken at 9 - 9 in FIG. 8 , with the gouge filled with snow.
[0024] FIG. 10 is a plan view of a toe pick hole in an ice surface.
[0025] FIG. 11 is a section taken at 11 - 11 in FIG. 10 , with the hole filled with snow.
DETAILED DESCRIPTION OF THE INVENTION
Definitions
[0026] The following terms are used throughout this application in accordance with these definitions, unless a different interpretation is required by the context.
[0027] The terms “ice rink” and “rink” refer to ice having a horizontal surface used for ice skating, including recreational, professional, hockey, or figure skating, whether located indoors or outdoors, constructed or naturally occurring (such as a pond), or cooled naturally or by refrigeration.
[0028] The term “rut” refers to local, concave imperfections in the surface of an ice rink, including grooves, nicks, cracks, and gouges. (Ruts are typically caused by ice skate blades, falls, and hockey sticks.)
[0029] The term “snow” refers to particles of frozen water removed from the surface of an ice rink by scraping, including scrapings of the top layer of the ice, skater-generated snow, fallen snow, sleet, frozen rain, condensation, or other precipitation on the surface, including any liquid water mixed with them. Since “snow” includes associated liquid water, its nature will vary greatly depending upon wetness, compaction, temperature, slushiness, particle size, flowability, stickiness, etc.
[0030] The term “average thickness”, in a reference to a layer of snow being removed by a scraper blade from an ice surface, means the theoretical thickness the layer would have if the surface were perfectly and uniformly flat and level.
[0031] The term “box” is used in accordance with its dictionary definition relating to machines, e.g., an enclosing casing or part in a machine.
[0032] The term “cut”, used as a noun, means a series of passes of the machine, usually overlapping, that cover a desired rink area, as one would use that term with respect to mowing a lawn or field.
The Ice Resurfacing Machine
[0033] FIG. 1 shows an ice resurfacing machine according to the present invention resting on ice surface 10 . The machine consists of four groups of components—vehicle 12 , resurfacing attachment 14 , lifting and leveling assembly 16 connecting them, and water supply system 17 .
[0034] Vehicle 12 has wheels 18 , steering mechanism 20 , driver's seat 22 , a motor (not shown), a battery (not shown), and a standard trailer hitch receiver 24 . The particular vehicle shown is a golf cart with an electric motor. Other vehicles, such as all-terrain vehicles and tractors, may be used for outdoor rinks. As an alternative to battery power, motors powered by compressed gas such as butane or propane may be used for indoor rinks.
[0035] Water supply system 17 consists of water supply tank 26 in vehicle 12 behind driver's seat 22 . Located within tank 26 is water pump 27 , which is connected to water supply line 28 via water regulator 29 , which may be manually regulated to vary the volume of water flow. Water regulator 29 is a ball valve. Alternatively, water supply system 17 may be mounted on resurfacing attachment 14 .
[0036] As shown in FIGS. 2, 3 , and 4 as well as in FIG. 1 , resurfacing attachment 14 includes snow box 30 , which is open at the bottom and enclosed on the remaining five sides. It may be called either a “snow box”, because of its function of generating, using, and collecting “snow”, or an “ice box”, because of its location and end product. It is made of sheet metal, but other materials such as plastic compositions may also be used. Attached to the top wall of snow box 30 is support frame 32 , which consists of welded vertical, lateral, and longitudinal square metal tubes.
[0037] Ice blade mounting bar 34 , which is shown in FIG. 2 , extends laterally across the width of box 30 and is fastened to the side walls of box 30 . Ice blade 36 , which is made of tempered steel, is bolted to mounting bar 34 by two bolts in longitudinal slots in blade 36 . The slots are parallel to the longitudinal axis of the vehicle. Mounting bar 34 and blade 36 are inclined at an angle of 12° to the surface of the ice. By loosening the bolts, sliding blade 36 in the slots forward or backward to a new position, and re-tightening the bolts, the height of the sharp cutting edge of the blade with respect to the bottom edges of the box may be varied. It is not possible, or necessary, to vary the height of the blade during resurfacing. Usually the edge of blade 36 will be coplanar with the bottom edges of box 30 . For a dry cut to reduce ice thickness, the blade edge will extend below the box edges by ⅛ inch or so. The slots are sufficiently long to allow the blade edge to protrude ¼ inch below the box edges.
[0038] Water distributor 38 is a tube secured to the rear wall of snow box 30 by hangers 40 . A number of aligned holes 42 spaced V 2 inch apart in the tube are aimed at the rear wall of box 30 . One end of water distributor 38 is connected to water supply line 28 at a 90° elbow.
[0039] Also attached to the rear wall of snow box 30 is towel holder 43 . Removably connected by studs to towel holder 43 are water spreader towel 44 and towel backing bar 46 , which in turn are attached to each other. This connection enables the towel and backing bar to be quickly replaced so that the towel can be allowed to dry. Spreader towel 44 is made of terry cloth, while backing bar 46 is made of stainless steel. Towel 44 lies on the ice over the width of box 30 . A spreader towel is sometimes referred to as a “mat”.
[0040] Lifting and leveling assembly 16 includes at its front end a drawbar (not shown) which engages and is removably connected to hitch receiver 24 . Post 52 is fixed to the drawbar. Pivotally connected to post 52 are central support arm 54 and two lever links 56 , which in turn are pivotally connected at their rear ends to outer support arms 60 and farther forward to the piston of hydraulic unit 58 comprising a cylinder, piston, motor, pump, and fluid reservoir. Two support bars 62 are pivotally connected at their front ends to the drawbar, at their rear ends to snow box support frame 32 , and in between to the lower ends of outer support arms 60 . By virtue of their threaded parts, the three support arms 54 , 60 are manually adjustable, and may be lengthened or shortened in turnbuckle fashion. The lifting and leveling assembly is a three point hitch, which was commercially available before the present invention was conceived.
[0041] Adjustment of support arm 54 levels the lower edges of snow box 30 from front to rear. Adjustment of support arms 60 levels the lower edges of the snow box 30 from side to side. Actuating hydraulic unit 58 to extend the piston lifts snow box 30 vertically, while actuating it to retract the piston lowers snow box 30 so that it rests on the surface of the ice.
Operation of the Ice Resurfacing Machine
[0042] The resurfacing machine may be used in three different modes—routine resurfacing mode, heavy snow removal mode, and ice thickness reduction mode. Routine resurfacing, the mode of its most frequent use, is appropriate after skaters have created snow and there has been no significant precipitation, extreme wear, or degradation. Heavy snow removal is appropriate when precipitation has fallen on an outdoor rink. Ice thickness reduction is appropriate when the thickness of the ice has become or is becoming thicker than 1 inch. It will be understood that other factors may be involved (for example, heavy snow resulting from especially vigorous skating, or falling and freezing condensation from the roof of an indoor rink) and that there is no bright line between the conditions warranting the selection of the appropriate mode. Usually, when either of the latter two modes is used, the operation will be immediately followed by a routine surfacing.
[0043] The heavy snow removal and ice thickness reduction modes are used without applying water to the surface of the ice and hence are sometimes referred to as a “dry cut”. Towel 44 is removed for either of these modes. In the routine resurfacing mode, blade 36 is adjusted and secured so that it is coplanar with the bottom edges of box 30 . In the heavy snow removal mode, blade 36 is either at that coplanar position or is adjusted and secured so that it is above the coplanar position. In the ice thickness reduction mode, blade 36 is adjusted and secured so that it is below the coplanar position.
[0044] The routine resurfacing mode is carried out as follows. The operator fills tank 26 with hot water having a temperature in the range of from about 95° F. to about 120° F. and, with the box in the raised position, drives vehicle 12 to the desired starting position on the ice. Then he or she lowers box 30 until it rests evenly on the surface of the ice, turns on pump 27 , and drives around the ice in a desired pattern. Typically the pattern is a series of slightly overlapped ovals with ever-decreasing radii, possibly with an initial swath along the longitudinal axis of the rink to avoid ending with irregularities due to turning radius limitations. If the box fills completely with snow, the operator drives to a location either on the ice or on a smooth, level surface contiguous with the ice, stops the vehicle, and raises box 30 , leaving the snow exposed on the surface, so that the “dumped” snow may be shoveled into a container such as cart, either then or later.
[0045] As so used in the routine resurfacing mode, the ice resurfacing machine depicted in the drawings will resurface about 8,000 sq. feet before box 30 fills up with snow to the extent that dumping is required. As used in either of the waterless modes, the box fills up more quickly and more frequent dumping is required. Also, the lower the position of blade 36 , the more snow is collected and the more frequently dumping is required.
[0046] Whenever the machine is stopped on the ice, water pump 27 should be turned off and box 30 should be raised. Otherwise, the hot water will melt the ice and the towel or box will stick to the ice. This is accomplished manually by “Water On/Water Off” and “Snow Box Up/Snow Box Down” controls in vehicle 12 .
[0047] In the routine resurfacing mode, with the edge of blade 36 coplanar with the bottom edge of box 30 , blade 36 will lightly scrape the surface of the ice and remove the snow already on the surface of the ice and a very thin layer of the ice. I estimate that the average thickness of this layer is about 1/32 inch, and certainly less than 1/16 inch. Blade 36 also levels the ice by removing high spots and bumps.
[0048] If necessary to generate sufficient snow to fill the ruts in the surface of the ice, blade 36 may be lowered slightly. The blade may be effectively lowered in a small increment by stopping vehicle 12 and adjusting central support arm 60 so as to lower the front of box 30 , which avoids the need to move blade 36 with respect to blade mounting bar 34 as described above.
[0049] During routine resurfacing, the operator manually controls water regulator 29 to adjust water flow as desired. Increased flow is warranted by higher vehicle speed, resurfaced areas that appear to have insufficient water, creating new ice at the beginning of the skating season, and building up low spots. Decreased flow is warranted by reduced vehicle speed (as may be necessary for turning corners) and standing water. The slower the vehicle speed, the better the quality of the ice resurfaced.
[0050] The ice resurfacing machine according to the invention requires very little maintenance. The operator needs to make sure the batteries have the proper charge and water levels. Most golf carts require a monthly water fill. The scraper blade, though it holds a good edge and is very durable, requires sharpening from time to time. Also, the individual components are relatively light and can be easily moved and handled by one or two people.
The Ice Resurfacing Method
[0051] FIG. 5 shows resurfacing attachment 14 being used to resurface ice in the routine resurfacing mode, as it is being towed toward the right. Blade 36 is scraping ice surface 10 so as to create snow 64 , most of which passes over blade 36 and proceeds to the rear of box 30 . The snow is collected at 66 in the buildup just ahead of blade 36 and at 67 at the rear of box 30 .
[0052] Meanwhile, water pump 27 pumps pressurized hot water from tank 26 , through line 28 , and into water distributor 38 . Pressurized water issuing from holes 42 in distributor 38 strikes the rear wall of box 30 and flows down its surface due to gravity and surface tension, as shown symbolically at 68 , thereby further distributing the water in the transverse direction as it falls onto ice surface 10 . Finally, towel 44 spreads the water uniformly across the surface of the ice, where it will freeze to form good ice, typically within a few minutes.
[0053] FIGS. 6 through 11 show three types of ruts commonly made in the ice by skaters. FIGS. 6 and 7 show turn groove 80 , which has a maximum depth of 80 D. FIGS. 8 and 9 show slip or stop gouge 82 , which has a maximum depth of 82 D. FIGS. 10 and 11 show toe pick hole 84 , which has a maximum depth of 84 D. FIGS. 7, 9 , and 11 show these ruts filled with snow, as will be explained next. Normally depths 80 D and 84 D are greater than 1/16 inch, but they sometimes go as deep as 1 inch (i.e., all the way through the ice). Normally depth 82 D is less than 1/16 inch. Thus, the suffix “D” refers to the maximum depth of each of these ruts.
[0054] FIG. 5 depicts six ruts in the surface exaggeratedly at 70 , 72 , 74 , 76 , 78 , 79 , going from right to left. These ruts are in different locations with respect to box 30 , blade 36 , and towel 44 , but will be used here to illustrate the sequence of the inventive resurfacing method for a single rut. Rut 70 is empty, and rut 72 is empty or nearly so. Rut 74 is partly or complete filled by collected snow from 66 . Rut 76 differs from rut 74 in that its depth has been slightly reduced because a thin layer has been scraped off the surface of the ice by blade 36 . Rut 78 has been filled, or topped off, by collected snow from 67 . Such snow is shown in FIGS. 7, 9 , and 11 at 86 , 88 , 90 . Finally, rut 79 is filled with water, since the hot water filled the interstices of and melted the snow that had filled the rut.
Specific Data
[0055] Specific data for the resurfacing machine shown in the drawings are as follows:
Dimensions 121 in. long × 48 in. wide × 54 in. high Weight 950 pounds Top speed 12 mph Capacity of water tank 26 25 gallons Capacity of water pump 27 750 gallons per hour Exterior dimensions of snow box 30 48 in. wide × 24 in. long × 10 in. high Approximate time for routine 10 minutes or less resurfacing of 7,000 sq. ft. ice skating rink
Reference Character Table
[0056] The following table lists the reference characters and names of features and elements used herein, with asterisks indicating groups of features and elements:
Ref. Paragraph Char. Feature or element introduced in FIGS. shown in 10 ice surface 0027 1, 2, 5, 6-11 12 vehicle* 0027, 0028 1 14 resurfacing attachment* 0027, 0030 1, 2-5 16 lifting and leveling 0027, 0034 1 assembly* 17 water supply system* 0027, 0029 1 18 wheels 0028 1 20 steering mechanism 0028 1 22 driver's seat 0028 1 — battery (not shown) 0028 — — motor (not shown) 0028 — 24 standard hitch receiver 0028 1 26 water supply tank 0029 11 27 water pump 0029 1 28 water supply line 0029 1-3 29 water regulator 0029 1 30 snow box or ice box 0030 1-5 32 snow box support frame 0030 1-5 34 blade mounting bar 0031 2 36 ice blade 0031 1, 2, 5 38 water distributor 0032 1-5 40 hangers 0032 2-4 42 holes 0032 3 43 towel holder 0033 1, 2, 3 44 water spreader towel 0033 1, 2, 4, 5 46 towel backing bar 0033 2 — drawbar (not shown) 0034 — 52 post 0034 1 54 central support arm 0034 1 (adjustable) 56 lever links 0034 1 58 hydraulic unit 0034 1 60 outer support arms 0034 1 (adjustable) 62 support bars 0034 1 64 snow 0045 5 66 collected snow toward 0045 5 front of box 67 collected snow toward 0045 5 rear of box 68 water 0048 5 70 rut ahead of box front 0048 5 wall 72 rut just behind box front 0048 5 wall 74 rut beneath collected 0048 5 snow at 66 76 rut behind blade 0048 5 78 rut beneath collected 0048 5 snow at 67 79 rut behind towel 0048 5 80 turn groove 0047 6, 7 80D maximum depth of turn 0047 7 groove 82 slip or stop gouge 0047 8, 9 82D maximum depth of slip 0047 9 or stop gouge 84 toe pick hole 0047 10, 11 84D maximum depth of toe 0047 11 pick hole 86 snow filling turn groove 0047 7 88 snow filling slip or stop 0047 9 gouge 90 snow filling toe pick 0047 11 hole
[0057] It will be understood that, while presently preferred embodiments of the invention have been illustrated and described, the invention is not limited thereto, but may be otherwise variously embodied within the scope of the following claims. It will also be understood that the method claims are not intended to be limited to the particular sequence in which the method steps are listed therein, unless specifically stated therein or required by description set forth in the steps. | An ice resurfacing machine for small and medium-size indoor and outdoor ice skating rinks comprises a light towing vehicle, a resurfacing attachment, and a lifting and leveling assembly connecting them. To eliminate ruts in the ice, the machine removes only a thin layer of ice by scraping, fills the ruts with “snow” created by the scraping, skating, and precipitation, and adds water to fill the rut. The cold from the base ice and/or the atmosphere freezes the water and thus eliminates the rut. The machine may also be used to remove heavy snow or reduce the thickness of the ice. | 4 |
RELATED APPLICATION
[0001] This application is based upon and claims the benefit of Provisional Application 60/240,198, filed Oct. 13, 2001.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to a new and improved way of attaching a welded wire soil-reinforcing grid to a facing system for use in mechanically stabilized earth (MSE) retaining structures. The invention is an improvement over the prior art in that it places even stress on the tension elements, defined herein as the longitudinal wires of the soil-reinforcing grid. Further, the present invention allows a welded wire grid to translate in a horizontal plane with respect to the facing panel.
[0003] One form of prior art relies on attaching welded wire reinforcing grid by forming a loop or special crimp in individual longitudinal wires of the grid. The loops are formed by bending the wire 180° and welding the bent end to the longitudinal wire. This forms an integrated loop. This apparatus appears in U.S. Pat. No. 4,725,170-Davis. The loop of the welded wire grid is then placed through a coiled anchor that is cast into the back of a concrete face panel. The loop of the soil reinforcing grid and anchor are in a vertical plane which is perpendicular to the back face of the panel.
[0004] In another prior art MSE system the longitudinal wire is bent 90° and attached with a plate and bolt to the back of the facing unit. In another system the longitudinal wire is crimped and joined to an anchor with a connection pin. These can be seen in U.S. Pat. No. 5,749,680-Hilfiker and U.S. Pat. No. 4,324,508-Hilfiker, respectively. The arrangement of patent U.S. Pat. No. 5,749,680 allows the reinforcing grids to translate in a horizontal plane with respect to the facing panel.
[0005] Other prior art places the transverse wire of the welded wire grid work behind a loop that is formed in a panel anchor. The welded wire grid is attached to the panel anchor with a connection pin. This appears in U.S. Pat. No. 5,259,704-Orgorchock.
[0006] Still other prior art bends a single longitudinal wire 180° to form a paired longitudinal wire hairpin configuration. Welded to the paired longitudinal wires are transverse wires, which form a welded wire grid work. This combination forms an integral loop at the lead end of the soil-reinforcing element. The anchoring element protruding from the back of a panel is a formed loop. The soil-reinforcing element and loop are joined with the aid of a snap together mechanism. This can be seen in the prior art Alviterra connection shown in FIG. 1.
[0007] One block system utilizes a reinforcing element having parallel longitudinal wires with loops formed in each end. Each longitudinal wire is placed in counter bores formed in the top surface of a block. Rods are inserted through the counter bores and loops to secure the reinforcing element in the block. This arrangement can be found in U.S. Pat. No. 5,487,623-Anderson.
[0008] A second block system utilizes a flat polymeric soil reinforcing mat that is placed between blocks. The soil reinforcing mat is sandwiched between the blocks. The blocks are secured together by a pin that anchors the grid. This can be seen in U.S. Pat. No. 4,914,876-Forsberg.
[0009] U.S. Pat. No. 6,050,748 -Anderson, discloses a variety of loop connectors on the ends of the longitudinal wires of soil reinforcing mats to secure these mats to face elements. Of particular interest are the connections seen in FIGS. 47 to 52 of this patent which include overlapping loops which are engaged between or over connecting elements embedded in the face panels.
SUMMARY OF THE INVENTION
[0010] A principal object of the present invention is to provide an apparatus and method for attaching the face of an earthen retaining structure to a soil-reinforcing element through means of loops formed by parallel longitudinal wires of the element. The loops are overlapped on top of one another. The loops can be formed in numerous fashions. The use of separate wires makes manufacturing of the loops easier. The loops are attached to the face so that the soil-reinforcing element is free to rotate about the axis of the loops. This allows the soil-reinforcing element to be skewed at an angle to the back face of the structure. An advantage of the overlapping loops is that when a force is applied to the longitudinal wires each loop tightens upon itself. This tightening increases the connection capacity. In addition, the connection is mechanical and does not rely on the weld shear of a transverse wire. Further, the soil-reinforcing element can be rotated to pass obstructions. Additionally, since two longitudinal wires are utilized in lieu of one there is twice the strength available.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] [0011]FIG. 1 is a plan view showing the prior art Alviterra mat;
[0012] [0012]FIG. 2 is a top plan view of a first embodiment of the connection of the present invention;
[0013] [0013]FIG. 3 is a side elevational view of the first embodiment connection;
[0014] [0014]FIG. 4 is an end elevational view of the first embodiment connection, shown connected to an anchor element;
[0015] [0015]FIG. 5 is a side elevational view of the first embodiment connection, shown connected to a generally U-shaped anchor element embedded in a concrete face panel;
[0016] [0016]FIG. 6 is an elevational cross-sectional view of first modification of the first embodiment connection wherein a flanged sleeve is inserted through the coils of the connection;
[0017] [0017]FIG. 7 is a top plan of a second modification of the first embodiment connection, wherein the looped wires of the connection are bent 180° about themselves and welded together at their lead ends;
[0018] [0018]FIG. 8 is a side elevational view of the connection of FIG. 7;
[0019] [0019]FIG. 9 is a top plan view of a third modification of the first embodiment connection wherein the looped wires of the connection are bent 180° about themselves and twisted together;
[0020] [0020]FIG. 10 is a top plan view of a second embodiment of the connection of the present invention;
[0021] [0021]FIG. 11 is a top plan view of a third embodiment of the connection of the present invention;
[0022] [0022]FIG. 12 is an end elevational view of the third embodiment connection;
[0023] [0023]FIG. 13 is a side elevational view of the third embodiment connection;
[0024] [0024]FIG. 14 is a first modified version of the third embodiment connection wherein the loops are kinked;
[0025] [0025]FIG. 15 is a side elevational view of the first embodiment connection, shown connected to concrete block face elements;
[0026] [0026]FIG. 16 is a side elevational view of the first embodiment connection, shown attached to a cast concrete face element having a bifurcated shelf for receiving the connection;
[0027] [0027]FIG. 17 is a side elevational view of the first embodiment connection, shown attached to a cast concrete face element having an open shelf for receiving the connection;
[0028] [0028]FIG. 18 is a side elevational view of the first embodiment connection, shown attached to a welded wire face element;
[0029] [0029]FIG. 19 is a side elevational view of the first embodiment connection, shown secured between two concrete facing elements;
[0030] [0030]FIG. 20 is a top plan view of the FIG. 19 arrangement, showing the connection to the lower face panel shown in FIG. 19, with the upper panel removed;
[0031] [0031]FIG. 21 is a top plan view showing a modified version of the arrangement wherein the connection is held between segmental concrete panels, and the panels are made up of block-like elements;
[0032] FIGS. 22 is a side elevational view of the arrangement shown in FIG. 21;
[0033] [0033]FIG. 23 is a top plan view of an arrangement wherein the connection is between block elements and the pin securing the connection to the elements does not tie successive rows of block elements together; and
[0034] FIGS. 24 to 26 are top plan views illustrating how the connection of the present invention allows the soil reinforcing grids attached to various forms of face elements to translate in a horizontal plane relative to the face elements.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
First Embodiment
[0035] The first embodiment of the present invention consists of a welded wire grid 1 containing paired longitudinal wires 2 A, 2 B that are substantially parallel to one another. Cross members 3 are joined to the longitudinal wires in a perpendicular fashion by welds at their intersections 4 . The lead ends of the longitudinal wires are manufactured into a coil-loop 5 by wrapping the longitudinal wire around a pin. This forms a through-hole 6 in the end of the wire. The paired longitudinal wires are deflected inward toward one another so the through-holes overlap. The welded wire grid is attached to the back of a concrete element C by placing the coiled-loop between the legs of anchor elements 8 (see FIG. 5). The anchor elements 8 are C-shaped and each consist of a top leg 9 and a bottom leg 10 , each leg having a hole 11 extending therethrough of approximately the same diameter as the opening in the coil-loop. A rebar 7 extends within the concrete element C and through the bight portion of the anchor element 8 . Through the intersecting holes in the anchor and the coil-loop, a bolt or a pin 12 is placed. This ties the grid to the concrete panel 13 (see FIG. 5).
[0036] To prevent the longitudinal wires from separating, until such time that a pin is passed through the anchor and the coil, the coils can be welded together or a hollow tube 14 can be placed through the coil-loop opening and the ends 15 flared outward as shown in the modification of FIG. 6. This tube will keep the holes from each coiled longitudinal 2 A, 2 B wire in line. The coiled assembly is then fastened to the anchor.
[0037] The modification of the first embodiment connection shown in FIGS. 7 and 8 embodies a welded wire grid 1 having paired longitudinal wires 2 A, 2 B that are substantially parallel to one another and cross members 3 welded to the longitudinal wires at the intersections 4 . The lead ends of the longitudinal wires are laid over one another, with their ends bent 180° upon themselves, as may best be seen from FIG. 7. The loops are resistance welded to one another by “W” at their lead ends and where the distal portions of the loops cross (see FIG. 7).
[0038] The third modified version of the first embodiment shown in FIG. 9 is similar to the second modification of FIGS. 7 and 8, except that in the FIG. 9 modification no welds are provided between the loops and the distal portions of the loops are twisted about themselves at “T.” This twisted connection prevents the loops from straightening and releasing under the application of tension forces to the wires 2 A and 2 B.
Second Embodiment
[0039] The second embodiment of the present invention is shown in FIG. 10 and comprises welded wire grid 16 having paired longitudinal wires 2 A, 2 B that are substantially parallel to one another. Cross members 3 are joined to the longitudinal wires in a perpendicular fashion by a welds at their intersections 4 . The lead longitudinal wires are manufactured into a loop by bending the longitudinal wire 180° around a pin and welding the ends 17 of the wires to the longitudinal wires. This forms a loop 18 in the end of each longitudinal wire. The looped longitudinal wires are deflected inward toward one another so the through-holes 19 formed therein intersect. The wires are connected with a weld 20 , or a flared tube as previously described. The welded wire grid is then attached to the back of a concrete element by placing the loops between the legs of an anchor element. The anchor element corresponds to previously described element 8 and comprises a top leg and a bottom leg, each leg having a through-hole of approximately the same diameter as the opening in the coil loop. Through the intersecting holes in the anchor and the loops, a bolt or a pin is placed, similarly to what is seen in FIG. 5. This ties the grid to the concrete panel.
Third Embodiment
[0040] A third embodiment of the present invention, as shown in FIGS. 11 to 13 , comprises a welded wire grid 1 having paired longitudinal wires 2 A, 2 B that are substantially parallel to one another. Cross members 3 are joined to the longitudinal wires in perpendicular fashion by welds at their intersections 4 . The lead longitudinal wires are deflected toward one another. The ends of the longitudinal wires are bent around one another in an over-lapping fashion and welded together, forming a closed loop 7 .
[0041] The wires are placed in anchor as previously described (see FIG. 4). In order to make movement of the closed loop more restrictive, it can be formed with a kink, as shown in the modified version of the third embodiment shown in the modification of FIG. 14.
Use of the Connection
[0042] Each of the embodiments can be attached to concrete panels as shown in FIGS. 16, 17, 19 and 20 , blocks as shown in FIG. 15, or a welded wire-facing element as shown in FIG. 18. Attachment can be made with an anchor 8 that is attached to the facing and captures the loops between the protruding top and bottom portions 9 , 10 . In the block arrangement of FIG. 15, the element 8 is connected to the blocks B with a bolt or pin 22 that is “L” shaped.
[0043] The panel arrangements can be made of cast concrete that is manufactured into a face panel D (FIG. 16) to provide bifurcated shelf having a slot 22 providing an opening that the loops are placed through, or as a simple shelf 24 (FIG. 17) upon which the loops rest. The soil-reinforcing elements are joined to the panels P with a pin 25 .
[0044] The wire face arrangement (FIG. 18) employs a C-shaped anchor element 8 A similar to the element 8 previously described. The C-shaped element is placed to the front of the facing element, designated 26 , and captures two transverse wires of the facing element. The soil-reinforcing element is attached by placing a bolt or pin 12 through the opening in the anchor and the coil loops.
[0045] The coil loops can also be attached by capturing the loops between two concrete facing elements 29 A, segmental concrete panels or segmental concrete blocks 29 B, as shown in FIGS. 19 to 22 . In these arrangements, the loops are placed in a void that is cast into the top surface of the concrete element. A segmental concrete element is placed on the soil-reinforcing element. Cast into the void is a hole 30 that will allow a pin 32 to be set in the panel and passed through the soil-reinforcing loop opening securing it from removal. The pin can pass into the segmental element above.
[0046] [0046]FIG. 23 shows a connection to a block arrangement in which the pin 34 for connecting the loop of the invention does not tie into the block 29 C row above, but is between successive paired blocks of above. The block 29 C is shaped in such a manner that the pin does not tie the second row of blocks together. It would be possible to pass the pin into the third row of blocks. This would tie every other row of blocks together.
[0047] FIGS. 24 - 26 illustrates how the connection of the present invention allows a welded wire soil reinforcing grid to translate in a horizontal plane with respect to the facing member to which it is attached.
[0048] While specific embodiments of the invention have been illustrated and described, it should be understood that the invention is not intended to be limited to these embodiments, but rather as defined by the claims. | A connection for securing the longitudinal wires of a soil reinforcing mat to a face element for an earthen formation is provided by converging the lead ends of the wires toward one another and forming aligned coils distally on the lead ends. A pin extending through the coils secures the soil-reinforcing mat to the face element for pivotal movement relative thereto in a horizontal plane. A variety of means are provided to secure the coils against unwinding in response to tension force applied to the wires. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to vibration dampers particularly for use on engines or transmissions adapted to drive motor vehicles.
2. Related Art
Internal combustion engines experience torsional vibrations due to non uniform loading of the crankshaft from the cylinder pressure and the reciprocating parts of the engine. If the vibration becomes severe enough to damage the crankshaft or the accessories driven by the crankshaft, either the crankshaft must be redesigned or a method of controlling the vibration must be used. Elastomeric dampers may be used to reduce torsional, axial or bending vibration to an acceptable level. Elastomeric dampers behave like a combination of a tuned absorber and an energy dissipator. The tuning effect of the damper is achieved by the proper balance of elastomer stiffness and the inertia of the damper ring, while the energy dissipation is primarily determined by the inherent damping of the elastomer. Typically the damper may include a hub part adapted to be rigidly attached to the rotational shaft requiring damping, an outer inertia ring and an elastomeric material ring separating the ineretia ring from the hub part. An example of the foregoing type of vibrational damper is shown in Australian Patent Application No. 83399/87. Other examples are shown in Australian Patent Nos. 578170, 578846, 63868/86, 255913 and U.S. Pat. Nos. 1,944,233 and 4,710,152. There is also a growing tendency to drive vehicle accessories off the crankshaft of engines and when an elastomeric damper is mounted thereon, it is necessary to drive the accessories from the intertia ring of the damper. The foregoing would not apply where the shaft requiring balancing is in the transmission. This, to some extent has some disadvantageous effects on the performance of the damper.
SUMMARY OF THE INVENTION
The aim of the present invention is to provide improved designs of elastomeric dampers capable of damping torsional vibrations or torsional and bending vibrations which may be produced efficiently and which are safe and effective in operation. A further preferred aim of the invention is to provide a damper construction that enables accessories to be driven therefrom but which separates the vibration control function from the accessories drive function.
In accordance with a first aspect of the present invention there is provided an elastomeric damper comprising a hub section adapted for connection to a rotational shaft requiring balancing in an internal combustion engine, said hub section including a radially extending portion and an axially extending portion adjacent said radially extending portion, an annular inertia ring located inwardly of said axially extending portion and an elastomeric material arranged between an outer circumferential surface of said inertia ring and an inwardly directed circumferential surface of said axially extending portion, and a radially inwardly deformed section located on said axially extending portion at a position spaced from said radially extending portion clamping said inert ring in position separated from said hub section by said elastomeric material. Conveniently said hub section is formed by pressing, rolling or otherwise deforming material (preferably steel) plate.
In accordance with a second aspect of the present invention there is provided an elastomeric damper comprising a hub section adapted for connection to a rotational shaft requiring balancing in an internal combustion engine, said hub section including a radially extending portion and an axially extending portion adjacent said radially extending portion, an annular inertia ring located inwardly of said axially extending portion and an elastomeric material arranged between an outer circumferential surface of said inertia ring and an inwardly directed circumferential surface of said axially extending portion, said elastomeric material being preformed to include an axially extending part and at least one radial extending part located between the inertia ring and the radial extending portion of said hub section. Preferably, the elastomeric material is bonded to said inertia ring and said hub section.
In accordance with a third aspect of the present invention, there is provided an elastomeric damper comprising a hub section adapted for connection to a rotational shaft requiring balance in an internal combustion engine, said hub section including a radially extending portion and an axially extending portion adjacent said radially extending portion, a first annualar inertia ring located inwardly of said axially extending portion and an elastomeric material arranged between an outer circumferential surface of said first inertia ring and an inwardly directed circumferential surface of said axially extending portion, a second annular inertia ring located inwardly of said axially extending portion of said hub section between said first inertia ring and said radially extending portion, elastomeric material located between said first and second inertia rings and between said second inertia ring and said radially extending portion of the hub section.
Preferably, a radially inwardly deformed section located on said axially extending portion at a position spaced from said radially extending portion is provided with elastomeric material being located between said inwardly deformed section and said first inertia ring. In another preferred arrangement at least part of the aforesaid elastomeric material is formed by a preferred annular ring having an axially extending part and at least one radially extending part located between the first inertia ring and the radially extending portion of the hub section.
In accordance with a still further aspect, the present invention comprises providing an elastomeric damper comprising a hub section adapted for connection to a rotational shaft requiring balancing in an internal combustion engine, an inertia ring and an elastomeric material separating said inertia ring from said hub section, said hub section being manufactured from formed metal plate. Conveniently, the inertia ring is also manufactured from formed metal plate, with at least one (or both) of said inertia ring and said hub section having an axially extending section connected to a radially extending section, a free end of the or each said axially extending section being deformed radially to prevent axial relative movement between said hub section and said inertia ring.
According to a still further aspect, the present invention also provides an elastomeric damper comprising a hub section adapted for connection to a rotational shaft requiring balancing in an internal combustion engine and an annular damper section located radially outwardly of the hub section, said damper section having an axially extending annular part rigidly connected to said hub section, an annular inertia ring located inwardly of said axially extending portion and an elastomeric material located between an outer circumferential surface of said inertia ring and an inwardly directed circumferential surface of said axially extending portion. Conveniently, the damper section is formed by at least two discs of rolled, pressed or otherwise deformed metal plate to form an annular partially or wholly enclosed space housing the inertia ring. Preferably the at least two parts forming the annular space housing the inertia ring may be extended to the hub section. The elastomeric material might be a preformed ring or rings or might be introduced into the space surrounding the inertia ring in a liquid or flowable condition and set therein to provide the required elastomeric material.
In accordance with another aspect of the present invention, there is provided an elastomeric damper including a hub section defining an axial extending annular rim part, an annular inertia ring and an elastomeric material separating the axial extending ring part from the inertia ring, said hub section being characterised by a convex frusto conical portion configured to fit within an annular connecting member adapted to engage a rotational shaft to be dampened by said damper, said connecting member having a concave frusto conical region co-operable with the convex frusto conical portion of the hub section and fastener means for securing said hub section to said shaft. Conveniently one or more co-operable projections and complementary recesses are provided between the connecting member and the hub section to minimize or prevent relative rotation between these parts.
Conveniently, in any or all of the foregoing arrangements the outer surface of the axially extending portion may include grooves adapted to engage with belt drive means for driving vehicle accessories.
BRIEF DESCRIPTION OF THE DRAWINGS
Preferred embodiments of the present invention will hereinafter be described with reference to the accompanying drawings, in which:
FIG. 1 is an axial cross-sectional view of an elastomeric damper according to the present invention with one preferred embodiment illustrated in the upper half and a second preferred embodiment illustrated in the lower half of the drawing:
FIG. 1A is a partial sectional view of an end portion of the rim part of the hub showing an alternative embodiment;
FIG. 2 is a view similar to FIG. 1 showing further preferred embodiments;
FIG. 2A shows in partial section one possible preferred form of a preformed section of elastomeric material for use in the embodiment shown in the upper half of FIGS. 1 and 2;
FIG. 2B shows in partial section one possible preferred form of a preformed section of elastomeric material for use in the embodiments shown in the lower half of FIGS. 1 and 2;
FIG. 2C shows in partial section one possible form of preferred preformed elastomeric material for use in the embodiments shown in the lower half of FIGS. 1 and 2;
FIG. 3 is a longitudinal cross-sectional view of a damper constructed according to a still further preferred embodiment of the present invention;
FIG. 3A is a detailed sectional view of an alternative construction of the flange marked A in FIG. 3; and
FIG. 3B is a cross-sectional view along line 3B--3B of FIG. 3A.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, the elastomeric damper 10 comprises a hub section 11 formed by pressing a metal (preferably steel) plate. The hub section 11 includes a central region 12 including a plurality of openings enabling suitable bolts 13 to connect the hub section to a crankshaft 14. In the embodiment illustrated an intermediary mounting member 15 is used, however, if space permits in the engine cavity the central region 12 may connect directly to the crankshaft end.
Referring to the upper half of FIG. 1, the hub section 11 includes a radially extending section 16 and an axially extending section 17 extending from the outer end of the radially extending section 16. The outer surface of the axially extending section 17 which may include a plurality of V Grooves 18 (or the like) formed by any suitable means such as machining, pressing, rolling or any similar technique to enable accessories to be driven by a belt drive engaging the V grooves. An annular inertia ring 19 is located inwardly of the inner surface of the axially extending section 17 and is separated from the inner surface by an elastomeric material 20. The material 20 also extends down at least a short distance of the radial extending part 16 and an inwardly deformed flange 21 formed from the axially extending part so that metal to metal contact between the inertia ring 19 and the hub section 11 is prevented. Conveniently the flange 21 is deformed to the position illustrated after the inertia ring 19 has been located in the position shown.
The lower part of FIG. 1 illustrates a further preferred embodiment wherein two annular inertia rings 22 and 23 are employed. In this case the elastomeric material 20 extends over the inner surface of the flange 21, the axially extending part 17 and most of the radially extending part 16. The axially extending part 17 would normally need to be longer than the embodiment shown in the upper half of FIG. 1 to accommodate the two inertia rings. The inertia ring 22 is located adjacent the flange 21 and the inertia ring 23 is located between the ring 22 and the radially extending part 16. The ring 23 is spaced inwardly from the axially extending part and the elastomeric material 20 thereon. Conveniently an elastomeric material 24 (which may be the same composition as material 20 or different therefrom) is provided between the two inertia rings and between the second inertia ring 23 and the radially extending part 16. In this embodiment the inertia ring 22 acts to reduce torsional vibrations and the inertia ring 23 acts to reduce bending vibrations.
Reference will now be made to FIGS. 2, 2A, 2B and 2C. The elastomeric dampers 10 shown in the upper and lower halves of this drawing include inner parts that in operation are essentially similar to the dampers shown in FIG. 1. Thus, like features have been given the same reference numbers. In these embodiments, however, the outer surface of the axially extending part 17 is essentially plane and carries an elastomeric material sleeve 25. A further inertia ring member 26 is provided on the outer surface of the elastomeric material sleeve 25. This inertia ring member 26 is conveniently formed by pressing and rolling steel plate in a similar manner to the hub section 11. The member 26 includes an axially extending region 27, a radially inwardly extending flange 28 at one end of the axially extending region 27 and a rolled or otherwise deformed flange 29 located at the other end of the axially extending region 27. The outer surface of the axially extending region may include V-belt drive grooves 30 similar to 18 in the embodiment of FIG. 1. The reason for this arrangement is that elastomeric vibrational dampers cannot dampen out all vibrations although approximately 75% of the amplitude of vibrations can be removed. However, in some cases, it may not be desired to transmit such vibrations through the accessory drive as could be the case with the embodiment of FIG. 1. Providing an accessory drive from a further outer ring 26 that is separated from the hub by an elastomeric material 25 that is very much softer than the elastomeric materials 20, 24 will have the tendency of preventing the transmission of such vibrations that might remain to the accessory drive.
Various alternatives for the elastomeric materials are illustrated in FIGS. 2A, 2B and 2C. In FIG. 2B a preformed annular ring 40 is provided having an axially extending part 41 and an inwardly directed flange 42 that is adapted to rest against an inner face of the inertia ring 22 when assembled. The axial part 41 of the ring 40 is larger than the axial length of the outer circumferential surface of the ring 22 so that when the flange 21 is deformed inwardly the elastomeric material of the ring 40 is retained between the flange 21 and the inertia ring 22. In this embodiment, separate rings of elastomeric material 24 may be used. FIG. 2C shows an alternative embodiment for an elastomeric material ring 43 having an axial section 44 and two spaced radially extending parts 45 and 46. The parts 45, 46 are adapted to form the elastomeric material 24 and the axial part 44 forms the elastomeric material 20. FIG. 2A shows a further preformed elastomeric material ring 47 having an axial part 48 and a radial flange 49 which is capable of use in the embodiments shown in the upper halves of FIGS. 1 and 2. In these embodiments the ring (or rings) is/are placed into the inertia ring (or rings) prior to assembly with the radial extending flange (or flanges) being located between the outer inertia ring and the radial part 16 of the hub. A suitable bonding agent may be applied to appropriate mating surfaces where elastomeric material contacts metal prior to assembly of same. Conveniently the binding agent is a heat activated bonding material. Conveniently the respective parts of the damper, once assembled, are held in their correct positions by the deformed flange 21 or the flanges 21, 29 and thereafter the bonding agent is activated by heat treatment. If considered necessary, particularly with the embodiment shown in the lower halves of FIGS. 1 and 2, a removable annular wedge element 50 might be used to hold the inertia rings 22, 23 in correct position during heat treatment of the bonding agent, or perhaps during deformation of the flange 21 or the flanges 21, 29.
The deformable flanges 21, 29 might be simply an end part of the axially extending portions 17 of the hub. FIG. 1A, however, illustrates one preferred arrangement where an end tab member 51 might be provided which could be formed by a metal rolling technique simultaneously with rolling of the grooves 18. Such a tab member 51 would be readily deformed to the position 51' shown in dashed outline after insertion of the inertia rings and preformed elastomeric material place on the inertia rings, into the hub member. Another alternative might be to machine an end tab member similar to that shown in co-pending Australian Patent Application No. 83399/87, although this may be relatively more expensive. In some situations, it may be considered satisfactory to not provide any deformed tab member, flange or the like and simply rely on bonding the elastomeric material to the metal parts. This arrangement is also considered to be within the scope of the present invention. In some situations, it might also be considered appropriate to provide some mechanical treatment of the metal surfaces such as knurling or axially/circumferential splining to help retain the metal and elastomeric parts in correct position during operation of the damper. Preferred manufacturing methods that may be employed are as follows. The outer drive flange and rim may be blanked and formed from rolled sheet steel. The Poly "V"ee grooves 18 are roll formed if desired. The hub section 12 can be permanently attached or adhered by means such as welding, brazing, crimping, rolling, swagging, bonding, chemical adhesives, laminating etc.
The hub may be attached by means of fixed or removable fasteners such as central bolt or bolts, screws, rivets etc., and be formed by methods such as hot forging.
The intertia rings or weights 19, 22 or 23 may be produced from rolled steel bar or continuous strip in the hot or cold state by mechanical means, by forming into a circular ring or annular, and butt joint welded or adhered. The peripheral diameter can be rapidly sized by mechanical force or by removal of metal by methods such as centreless grinding, machining, finishing, to an accurate size and surface finish.
The elastomeric member may be produced from natural or synthetic rubber, polymers, or blends thereof. The manufacturing process can be from continuously extruded strip, which is dropped and glued or by compression moulding. Bonding agents may be applied to the elastomeric members by hot airless spray coating. A post vulcanisation bonding process can be used which also acts as a post vulcanisation cure process, desirable for optimizing lifecycle properties.
It will be appreciated from the embodiments illustrated that the damper 10 can be produced economically using plate pressing or rolling techniques with a minimum of machining requirements. The inertia rings 19, 22 and 23 are all simple annular shapes without any need for expensive machining. The assembly technique of using the deformable flanges 21 and 29 ensure that the products perform satisfactorily and safely, that is they prevent separation of the hub section from the inertia rings. Moreover, several of the damper embodiments allow for selecting differing elastomeric materials and differing inertia ring masses to provide greater flexibility of the performance characteristics of the damper.
Referring now to FIG. 3, the damper illustrated is formed by two plate members 60, 61 that have been rolled, pressed or otherwise formed into the desired shape as illustrated. The damper includes a hub section 62 adapted to be connected to a crankshaft 14 or the like and an inertia ring 63 enclosed within an outer annular space defined by radially outer parts of the members 60, 61. The hub section 62 is formed to have a convex frusto conical zone 64 that fits within a concave frusto conical zone 66 of a connecting member 65. The connecting member 65 has a cylindrical section 67 that fits over the crankshaft end 14. The inner member 61 may have an inner end 68 that is conformed to fit within the cylindrical section 67 of the connecting member 65. This inner end 68 may have one or more radially deformed elements adapted to fit within recesses in the inner surface of the connecting member 65 as shown at 69 to prevent relative rotation between the respective parts. A single bolt 70 with a frusto conical washer 71 is provided to secure the damper assembly hub section 62 to the shaft 14. The frusto conical configuration as shown provides a secure wedging effect to prevent the bolt 70 from loosening during operation.
At the outer ends of the frusto conical zone 64, the members 60, 61 merge into a radial extending flange region 72. In this region the members 60, 61, might, after assembly, be spot welded at one or more locations 73 to secure the members together. Any other technique adapted to automatic assembly procedures might also be used such as gluing. This radial flange region 72 might, if necessary, be stiffened by the use of a plurality of radially extending stiffening ribs 74 formed in at least one of the members 60, 61 as shown in FIG. 3A and 3B.
At the outer end of the radial flange section 72, the two members diverge at right angles from the section 72 to thereafter form a substantially enclosed annular chamber 75 housing the inertia ring 63. The chamber 75 includes inner and outer axial walls 76, 77 and two spaced radial walls 78, 79. Conveniently the free ends of the members 60, 61 may be formed by a rolled connection as shown at 80. Preferably the outer surface of the outer axial extending wall 77 includes rolled grooves 81 to enable an accessory drive belt to be driven therefrom. As is shown in FIG. 3, the inertia ring 63 may be secured in position within chamber 75 by a plurality of removable pins passed axially through bores 82 in the inertia ring and the radial walls 78, 79 of the chamber 75. In such a position the ring might be held securely and elastomeric material 83 can be introduced into the surrounding cavity while in a flowable condition and set in the cavity as illustrated. The securing pins are then removed from the bores 82 to provide the finished damper. Alternatively, preformed elastomeric material rings might be used placed around the intertia ring 63 prior to assembly of the members 60, 61 as illustrated. The closed construction of FIG. 3 does tend to protect the elastomeric material from possible contamination.
It should of course be appreciated that variations within the scope of this invention are anticipated. For example, the joining point 80 for the members 60, 61 could be varied along either of the faces 78, 79 if desired. Alternatively, the end of member 61 might extend axially across the outer surface of the elastomeric material, that is between the elastomeric material and the member 60. This will prevent any internal ripples caused by rolling the grooves 81 from contacting the elastomeric material. In a further embodiment, the radial flange section 72 might be extended radially outwardly with the ends of the members 60, 61 extending in opposite directions in a T configuration. In such an arrangement, two inertia rings one on either side of the flange section 72 could be employed. In this configuration, the ends of the members 60, 61 might be rolled or otherwise deformed inwardly to prevent the respective inertia rings coming loose. In addition to the foregoing, it is also proposed to employ two inertia rings within the chamber 75, each being separated by elastomeric material. The elastomeric material might, in such arrangements extend radially as is the case in the embodiment shown in the lower half of FIG. 1 or may extend axially.
The arrangement thus described can be readily produced by inexpensive metal forming and assembly techniques and therefore a relatively inexpensive but extremely safe and reliable damper can be achieved. | An elastomeric damper comprises a hub section configured for connection to a rotational shaft requiring damping in an internal combustion engine, and an inertia ring fitted within the hub section. The hub section includes a central region, an annular radially extending section extending radially outwardly from the central region, and an annular axially extending section extending axially with respect to the radially extending section. The axially extending section includes a radially inwardly directed portion. An annular inertia ring is located inwardly of the axially extending section, and an elastomeric material is located between the outer circumferential surface of the inertia ring and the inner circumferential surface of the axially extending section, the radially inwardly directed portion of the axially extending portion having a length terminating radially inwardly of the outer circumferential surface of the inertia ring, so that the inertia ring is retained between the radially inwardly directed portion and the radially extending section. | 8 |
BACKGROUND OF THE INVENTION
Barriers are commonly used at gas pump islands and drive-through businesses, such as restaurants and banks, to keep automobiles a safe distance from equipment and patrons. These barriers often take the form of poles, with or without continuous horizontal cross-members, made of steel or concrete.
Unfortunately, such barriers are generally designed to give catastrophic protection and may in fact inflict minor damage to automobiles and patrons following incidental contact. For example, car doors are particularly susceptible to paint loss or dents when accidentally opened into a barrier. Similarly, patrons of a business can suffer minor abrasions or bruising by absent-mindedly brushing against a barrier.
Similarly, the barriers themselves may also deteriorate over time following repeated minor contact with vehicles. At first, marks left thereon make them unsightly, and repeated damage may ultimately require them to be replaced.
There has therefore been a long-felt but unsolved need to provide resilient protection around such barriers to reduce or even eliminate minor damage caused by incidental contact therewith.
SUMMARY OF THE INVENTION
As has been described, the present invention is directed to addressing a need for protection against damage caused by incidental contact with barriers such as are often found at gas pumps and drive-through businesses.
In providing such protection, however, new and unexpected results manifest themselves. The barriers must, of necessity, be placed prominently so as to receive attention from the passing drivers and patrons. This prominence and attention make it highly advantageous to use the exterior surface of the present invention for commercial advertising. Alternatively, bright colors and designs on the exterior surface may be used to make the barrier yet more visible to cars and patrons.
The present invention also recognizes that barrier protectors are typically installed permanently outdoors, and are thus exposed to all weather elements. Accordingly, appropriate materials may be advantageously selected to make the protector waterproof, and its outer colored designs resistant to fading from prolonged exposure to sunlight.
The present invention further recognizes that once installed on barriers, an attractively decorated protector may be susceptible to theft. Accordingly, the invention is advantageously immobilized from the barrier to which it is attached.
It is therefore a feature of the present invention to provide a resilient protector over the hard outer surface of a barrier such as is typically found near pumps at gas stations or at drive-through businesses such as restaurants and banks.
It is another feature of the invention to provide a resilient protector whose exterior may be decorated with commercial advertising or other strident marks.
It is yet another feature of the invention to provide a protector that is durable in inclement weather conditions. In particular, the invention is advantageously waterproof and resistant to fading following prolonged exposure to sunlight.
It is another further feature of the invention to provide a protector that is immobile so as to deter theft.
It is a still further feature of the invention to provide a protector that is easy and inexpensive to manufacture and install, and yet is reliable and hard wearing in use.
These and other features of the present invention will be apparent to those skilled in this art from a detailed description of at least one preferred embodiment of the invention set forth below.
BRIEF DESCRIPTION OF THE DRAWINGS
This invention will be further described in connection with the accompanying drawings, in which:
FIG. 1 is an elevation view of the present invention, illustrating components in cutaway view.
FIG. 1A is a partial elevation view of the present invention, illustrating alternative gathering means as box 16.
FIG. 2 is a sectional view as shown on FIG. 1. Closing seam 20 is illustrated.
FIG. 3 is an elevation view of the present invention without cover 13, showing resilient membrane 11 prepared to be affixed to barrier 10.
FIG. 3A is a partial elevation view of the present invention without cover 13, showing alternative fastening means as box 30.
FIG. 4 is a similar elevation view of FIG. 3, this time showing cover 13 installed over resilient membrane 11, and prepared to be affixed to resilient membrane 11.
FIG. 5 is a situational view of the present invention installed on a barrier near a gas pump island, showing its advantage for commercial advertising. Optional pocket 53 is also illustrated.
FIG. 6 is an elevational view of another embodiment of the present invention, installed on a barrier with continuous horizontal cross-member 62. Again, a cutaway view shows hidden components.
FIG. 6A is a partial elevation view of another embodiment of the present invention, showing alternative closure means as line 63.
DETAILED DESCRIPTION OF THE INVENTION
Referring first to FIG. 1, barrier 10 is substantially surrounded by resilient membrane 11. Cover 13 with distal end 14 incarcerates resilient membrane 11. Distal end 14 provides casing 15 formed therein. Gathering means 16 is received into casing 15. Gathering means 16 may advantageously be a cinch, as illustrated, or alternatively an elasticated contractible cuff or a drawstring as illustrated by box 16 in FIG. 1A.
Referring now to FIG. 2, and looking down on barrier 10, it will be seen that the size and shape of resilient membrane 11 are predetermined so that when resilient membrane 11 is wrapped around barrier 10, a closing seam 20 is formed. Closing seam 20 runs vertically in this embodiment down the side of barrier 10.
FIG. 3 illustrates that closing seam 20 is held together with fastener means 30 at predetermined intervals along closing seam 20. Fastener means 30 may advantageously be a friction contact fastener, as illustrated, or alternatively self-adhesive tape, a string or an elasticated ring as illustrated by box 30 in FIG. 3A.
FIG. 3 also illustrates that resilient membrane 11 may be advantageously anchored to barrier 10 by adhesive 31. The adhesive can be "painted" or sprayed on barrier 10 at various places along its surface, or alternatively, only one spot of adhesive could be used as will be discussed. As illustrated, closing seam 20 is separated near base end 32 and resilient membrane 11 is rolled back on itself to reveal barrier anchor portion 33 of barrier 10, advantageously about 6" in length. Adhesive 31 is then applied to anchor portion 33. Resilient membrane 11 is rolled down so that the inner surface of membrane 11 makes contact with adhesive 31, and closing seam 20 is then fully restored.
FIG. 4 similarly shows that cover 13 may also be advantageously anchored to resilient membrane 11 by adhesive 31. Again, cover 13 is rolled back at distal end 14, to reveal cover anchor portion 40 of resilient membrane 11, advantageously about 6" in length. Adhesive 31 is then applied to cover anchor portion 40, cover 13 is rolled all the way down to allow contact thereof with adhesive 31, and cover 13 at distal end 14 is then closed around barrier 10 by pulling gathering means 16 tight and cutting any excess gathering means 16 off. In one embodiment, gathering means 16 is an electrical cable cinch which has one-way ratchets locking at a cinch point.
With regard to materials selection, it will be understood that the present invention may be made from any suitable material that will perform in the manner described. Nonetheless, experimentation has shown that resilient membrane 11 may be advantageously made of a waterproof Ethyl Vinyl Acetate foam, approximately 1/2 inch thick and 4-pound density. Cover 13 may be advantageously made of a waterproof acrylic cloth. Adhesive 31 may be advantageously a spray bonding agent, such as 80 High Tack, manufactured by 3M Company.
FIG. 5 illustrates the present invention's utility for the communication of data, such as artwork, pictures, commercial advertising and the like. Data 50 and background coloring 51 are imprinted on outer surface 52 of cover 13, advantageously by a process such as silk-screening. The coloring media used to imprint data 50 and background coloring 51 are advantageously selected to resist fading from prolonged exposure to sunlight. Optional pocket 53 may also be provided on outer surface 52 of cover 13 in which leaflets or other similar matter may be offered.
From the foregoing description, it will be understood that installation of the present invention involves first wrapping resilient membrane 11 around barrier 10 and holding resilient membrane 11 in position with fastener means 30 over closing seam 20. Resilient membrane 11 may then be temporarily rolled back on itself at base end 32 to permit adhesive 31 to be applied between barrier 10 and resilient membrane 11.
Cover 13 is then brought over resilient membrane 11 to incarcerate same. Cover 13 may then be temporarily rolled back on itself at distal end 14 to permit adhesive 31 to be applied between resilient membrane 11 and cover 13. Distal end 14 of cover 13 is then closed around barrier 10 by pulling gathering means 16 tight and cutting any excess off.
FIG. 6 illustrates an alternative embodiment of the present invention affording protection as described above to barriers with continuous horizontal cross-members. Barrier 60 has uprights 61 and continuous cross-member 62. Cover 13 in this mode is closed around uprights 61 and cross-member 62 with closure means 63 along its length. Closure means 63 may be advantageously a zipper, as illustrated, or alternatively a friction contact fastener as illustrated by line 63 in FIG. 3A.
The invention has been shown, described and illustrated in substantial detail with reference to at least one presently preferred embodiment. It will be understood by those skilled in the art, however, that changes and modifications may be made without departing from the spirit and scope of the invention which is further defined by the claims set forth hereunder. | Apparatus and method for protecting a barrier with a resilient pad, an objective of which being to reduce damage caused by incidental contact therewith. The protector includes a resilient membrane, advantageously made of foam, incarcerated by a cover. The outside surface of the cover may also be decorated with commercial advertising to take advantage of the prominent location of barriers at gas pump islands and drive-through businesses. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part application of U.S. non-provisional patent application Ser. No. 13/299,184 entitled “Method of Wound Treatment Using Condensation Warming” filed on Nov. 17, 2011 which is a continuation-in-part application of U.S. non-provisional patent application Ser. No. 12/537,755 entitled “Wound Ventilation System” filed on Aug. 7, 2009. The content of both of those applications are incorporated by reference as if set forth in their entirety herein.
BACKGROUND OF THE INVENTION
[0002] There is a great need for a better way of healing wounds. The present wound healing therapies are not doing an adequate job. There are too many wounds that do not heal and too many resulting complications and amputations.
[0003] As some examples, a wound site that becomes hypoxic is known to be at a greater risk of infection, a wound site that becomes hypothermic is thought to be at a greater risk of delayed healing, and a wound with improper moisture can impair healing. When wounds are too dry, they form a scab which slows the healing process. When wounds are too wet, maceration can occur, which also slows healing.
[0004] An improved way to heal wounds and avoid complications associated with the multiple conditions listed above is needed.
SUMMARY OF THE INVENTION
[0005] When everything is normal, the human body has a sense of physical ease or comfort associated with good health. A healthy body naturally maintains a closely regulated internal environment conducive to life. This healthy environment includes normal levels of blood flow, temperature, and moisture.
[0006] A wound typically disrupts one or more of these levels, placing additional stresses on the body. This disruption starts the healing process when the body is no longer in its healthiest state. The intervention strategy of this invention is to improve health and healing in all wounds by restoring to normal the physiological levels of blood flow, temperature, and moisture in situations where the body is unable to do this itself.
[0007] The disclosed device and method of wound treatment uses localized condensation warming in such a way as to restore at least these three physiological norms at the location of the wound simultaneously and continuously.
[0008] Near a wound site, normal blood flow decreases due to vascular damage as well as thermoregulatory vasoconstriction. A poor blood supply may result in wound hypoxia as the required oxygen needs to reach the wound via the bloodstream. Hypoxic wound tissue is easily infected and heals poorly. Condensation warming, which is the opposite of evaporative cooling, is provided to the wound bed by this invention. This warming can increase tissue perfusion and oxygenation by preventing local vasoconstriction and increasing the blood flow to the wound edges and surrounding tissues. This may also increase tissue oxygen tension, aid oxidative killing of microbes, and increase resistance to infection. Restoring blood flow to near normal levels with condensation warming has the potential to reduce delayed healing and infection in wounds where thermoregulatory vasoconstriction is occurring.
[0009] Normal temperatures are not typically maintained after a wound occurs because of the loss of an insulating layer of skin, resulting evaporative cooling, and less blood flow to bring warmth to the area. Temperature in the human body is both normal and optimal at 37 degrees C. Many wounds are substantially below this optimal temperature with the coldest sometimes being the most difficult to heal. Restoring normal temperature to the wound area with condensation warming has the potential to improve healing by speeding up cellular physiological functions.
[0010] Normal moisture levels are disrupted when the normal skin barrier is cut or damaged, exposing the inner tissues to the atmosphere. If the tissue cells dry out, they can lose perfusion and die in the process. Condensation occurring directly on cool wound tissues adds moisture to these wounds. Normal moisture levels may be restored with a wound dressing that mimics the natural moisture barrier originally provided by a healthy skin layer. The active dressing of this invention maintains a moisture balance by adding or removing moisture as needed.
[0011] Condensation warming has the potential to prevent hypoxia, hypothermia, and inadequate moisture levels at a wound site. The condensation warming and moisture addition functions of this invention are provided by a heated humidifier similar to those used in respiratory care. The moisture removal function is provided by a connected vacuum source. The heated humidifier and vacuum source work together as follows.
[0012] According to one form of the invention, a gas source, along with a liquid water source, enters the inlet of a heated humidifier. The humidifier uses heat energy to both heat the gas and to vaporize the water into the gas. Upon evaporating, the water vapor absorbs the latent heat of vaporization. This gas, now containing water vapor, exits the humidifier outlet at a dew point temperature of 37 degrees C. Next, the saturated gas and vapor enters the inlet of a substantially airtight wound dressing. Inside the dressing, moisture condenses directly on wound tissue cooler than 37 degrees C. The condensate releases its latent heat which gently warms the cool wound tissues. The condensate also adds its moisture to the wound tissues. The gasses, excess condensate, non-condensed vapors, and excess body fluids exit the dressing outlet, through a liquid trap, to a vacuum source.
[0013] Sensible heat is heat that changes the temperature of a substance. In comparison, latent heat (sometimes called hidden heat) is heat that is absorbed or released upon a change of state (gas, liquid, solid) of a substance without a change in temperature. The heat content difference between the two can be very significant. For example, the amount of sensible heat released when one pound of water is cooled by one degree Fahrenheit is 1 B.T.U. However, the amount of latent heat released when one pound of water is condensed is 970 B.T.U.s.
[0014] This invention primarily uses latent heat of vaporization in lieu of sensible heat. This is done because of the comparably larger quantities of heat that can be transferred at normal body temperature. The use of a dew point temperature which coincides with normal body temperature allows the latent heat to be released to the wound tissues at this optimal temperature. Lower temperatures may not sufficiently prevent vasoconstriction and higher temperatures may cause harm.
[0015] Latent heat is absorbed outside a wound dressing so it may be released inside the dressing. The change of state from a liquid to a vapor (evaporation) occurs above 37 degrees C. outside the dressing. The change of state from a vapor to a liquid (condensation) occurs at 37 degrees C. inside the wound dressing. Accordingly, a large amount of heat can be transferred from the outside to the inside of the dressing without the use of potentially harmful elevated temperatures. This heat is transferred by conduction which allows for deeper and quicker warming, as compared to convection. The heat is distributed within the dressing based on demand, with the coldest wound tissues receiving the greatest amount of heat. The amount of heat released is self-regulating and varies inversely with the temperature of the wound tissue.
[0016] Moisture is added to the wound bed with the near continuous condensation deposited on wound tissues at or cooler than 37 degrees C.
[0017] Moisture is removed from the wound bed when excess liquids are wicked up by the dressing material and continuously aspirated out of the dressing by the vacuum source.
[0018] Condensation warming improves wound tissue perfusion and oxygenation by preventing thermoregulatory vasoconstriction at the wound site. Sympathetically induced vasoconstriction may also be stimulated by pain, or blood-volume deficit, which may be treated separately.
[0019] Notably, the active wound dressing of this invention uses a singular approach to wound healing. Typical wound dressings are passive, and different designs each provide their own specific levels of permeability, absorptive capacity, and sometimes moisture addition. However, wounds are dynamic and changes in the wound may require changes in the absorption or addition of moisture, which a passive dressing cannot do. It can be difficult at times to properly match the dressing type to the wound. Utilizing the single active wound dressing of this invention eliminates having to choose from multiple dressing types under changing wound conditions. This approach simplifies decision making, eliminating possible errors.
[0020] These and still other advantages of the invention will be apparent from the detailed description and drawings. What follows is merely a description of some preferred embodiments of the present invention. To assess the full scope of the invention, the claims should be looked to as these preferred embodiments are not intended to be the only embodiments within the scope of the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 illustrates one embodiment of this wound warming system showing how it connects to other wound healing components. The relative size of the wound warming system may be different than shown.
[0022] FIG. 2 is the wound warming system of FIG. 1 installed in an enclosure and comprising a wound warming device.
DETAILED DESCRIPTION OF THE INVENTION
[0023] Hereinafter, the wound warming system may be referred to as a “wound incubator”, which is defined as an apparatus used to maintain environmental conditions suitable for the healing of wounds. Incubators are used in tissue culture rooms to grow stem cells, skin fibroblasts and other types of cells. Incubators are used in microbiology for growing bacteria and other microorganisms. This “wound incubator” is meant to mimic the fetal environment and encourage a rapid proliferation of new cells to replace those lost or damaged. A protective environment of controlled temperature and moisture is maintained inside the dressing. The result is an ideal wound environment for cellular growth much as a greenhouse provides the best environment for the growth of healthy plants.
[0024] FIG. 1 is a schematic showing the relationship between the wound incubator 1 , the wound dressing 18 , and the wound vacuum unit 22 . This drawing also shows how these components are connected with each other. The flow of gasses through the wound incubator 1 and the wound dressing 18 is powered by the suction force created by the wound vacuum unit 22 or other vacuum source. The direction of the flow of gasses through the various components is illustrated using arrows adjacent the conduits or tubes.
[0025] Referring again to FIG. 1 , air is always available to be freely drawn in through the air intake 2 after passing through a bacterial filter 3 . Flow rates are measured in liters/min. The flow rate is governed by a flow limiting device called the flow rate controller 8 . This device may be adjustable, but once a desired total flow rate is known, a constant flow rate makes component design and control simpler. A good constant flow rate device is a filtered orifice flow restrictor. A filter protects the tiny orifice from plugging up. Although not restricted to this range, the flow rate is typically in a range of 0.5 to 1.0 liters/min. This flow rate is preferably high enough to sufficiently warm most wounds and aspirate the dressing liquids; and low enough to be well below the capacity of the vacuum source. The flow rate controller 8 establishes a pressure differential that sets a boundary between atmospheric pressure upstream of the flow rate controller 8 and the negative pressure downstream of the flow rate controller 8 created by the wound vacuum unit 22 . When the vacuum unit 22 is run to create the pressure differential, the gas is drawn through the flow rate controller 8 into the humidifier inlet 10 .
[0026] The purpose of the humidifier 11 , its water source 16 , its heater 9 , and secondary heater 14 is to provide active warming and moisture addition by delivery of gas saturated with water vapor at 37 degrees C. to the wound dressing inlet 19 while minimizing condensation along the way. There are many ways to do this. For ease of explanation, FIG. 1 shows the humidifier 11 , the humidifier heater 9 and the secondary heater 14 as being separate components. Most modern heated humidifiers combine such components into a package. Heated humidifiers are also used when supplying respiratory gasses to a patient. They are available in many different designs, including: heated passover humidifier, by-pass humidifier, wick humidifier, vapor transfer cartridge, and capillary force vaporizers. Most would be appropriate for this application, providing they could be downsized for the lower flow rates. The humidifier could be controlled by using sensor 13 and maintaining a 37 degree C. dew point at this location. Preferably, the humidifier produces water vapor only. Unlike mist or droplets, molecules of water vapor are too small to transport bacteria to the wound, which could compromise the wound or create an infection. For the humidifier's water source, distilled water would typically be used and it could be supplied from a refillable container. A sterile IV type bag of water could also be used.
[0027] Between the humidifier outlet 12 and the wound dressing inlet 19 is the dressing delivery conduit or tubing 15 which places the humidifier 11 in fluid communication with the wound dressing 18 . This delivery tube 15 can be short to reduce heat loss. In any event, there can be some heat loss in this delivery tube 15 . If the temperature drops below 37 degrees C. at any location before the dressing inlet 19 , there would be unwanted condensation. One way to minimize delivery tube condensation is to add heat with a secondary heater 14 . This secondary heat source adds sensible heat to offset the loss of sensible heat in the delivery conduits as the vapor travels away from the humidifier 11 . This added heat would slightly exceed the heat loss and could be controlled by using sensor 17 located as close as possible or within dressing inlet 19 . In some forms, the secondary heater 14 can be a heating element or sleeve around some or all of the tube 15 between the humidifier 11 and the wound dressing 18 to try to maintain the temperature of the vapor at just above 37 degrees C. prior to the inlet 19 . In lieu of secondary heater 14 , condensation could also be minimized by using a by-pass humidifier, a heated delivery tube, an insulated delivery tube, or a heated wire breathing circuit.
[0028] There are many methods of controlling the chosen humidifier and associated heat sources so that heated gasses enter the wound dressing 18 slightly warmer than their 37 degrees C. dew point temperature. The wound dressing 18 may be chosen from among the many available existing negative pressure dressings and is designed to be substantially airtight. Most likely, an inlet tube connection 19 can be added to the typical dressing. This connection is preferably added in a location non-adjacent to the existing outlet tube connection 20 .
[0029] The wound is then warmed and moisture is added by condensing the vapor in the saturated gas into a condensate on a surface of the wound, such as the wound tissues, within the dressing 18 . This condensation of the vapor onto the wound releases the latent heat of vaporization, thereby locally warming the area of the wound and the surrounding tissues. Moisture is added to the wound bed with the near continuous condensation deposited on wound tissues at or cooler than 37 degrees C. Before evaporation threatens to dry tissues, evaporative cooling would lower the tissue temperature to 37 degrees C., causing the addition of more condensation and associated warmth. Because of this, the dressing environment is expected to remain fully saturated and at 37 degrees C.
[0030] Too much moisture or exudate at the wound site can cause maceration of the wound tissues and interrupt healing. Moisture can be removed from the wound bed when excess liquids are wicked up by a dressing material. As the liquids accumulate within the dressing, they can be continuously aspirated out of the dressing by the vacuum source (e.g., vacuum unit 22 ). Moisture is added and removed, as needed, to maintain a continuous moisture balance.
[0031] Autolytic debridement can liquify unwanted necrotic burden in a moist wound without harming healthy tissue. Continuous moisture balance makes continuous autolytic debridement possible. The accumulation of necrotic burden is managed with this maintenance phase of debridement.
[0032] Between dressing changes, when the wound is exposed, it is common practice to cleanse a wound. Wounds are cleansed to aid the removal of exudates, debris, slough and to prevent infections. The flow of condensate through this active wound dressing can also perform a cleansing function which is continuous and not relegated to just between dressing changes. The flowing condensate also dilutes the wound exudate, prevents thickening, and allows the vacuum source to remove more exudate.
[0033] One problem encountered during dressing changes is the adherence of wound tissue to the dressing material. Forcibly removing the dressing can cause trauma and disrupt the healing process. With this active wound dressing, the condensate created on the wound surface can soak and help soften the bonds between the tissue and dressing, minimizing the occurrence of this problem.
[0034] Condensation may form on the inside of the outer surface of the dressing 18 when its temperature is below 37 degrees C. To minimize this condensation, the dressing 18 may be covered with an insulated pad or blanket. This will reduce the heat loss and keep the dressing 18 warmer.
[0035] With respect to the vacuum source in the illustrated embodiment, dressing exit tubing 21 extends to the remotely-located wound vacuum unit 22 . This wound vacuum unit 22 may be chosen from the many types available. The operation of this unit is to be as per the manufacturer's instructions. This added “wound incubator” is not meant to change any of the operational or safety requirements of the typical negative pressure wound pump as recommended by the vacuum unit manufacturers. However, a wound vacuum unit is not necessary. Instead, another vacuum source, such as a wall outlet vacuum, may also be used along with a suction unit, regulating the vacuum and collecting the liquids. The vacuum source may also be the power source that creates flow or wound ventilation. This can eliminate the need for a fan or the necessity for pressure induced flow.
[0036] A wound site that experiences any degree of vasoconstriction is not receiving the optimal perfusion and oxygenation needed to provide a good environment for healing. By controlling dew point and condensation, both the temperature and moisture at the wound site can be advantageously regulated so as to restore the body's normal physiological levels including blood flow, temperature and moisture. The wounds having the greatest deviations from normal would be expected to benefit the most. The restoration of physiological norms may begin the healing process.
[0037] While FIG. 1 is used to show basic components and principles of operation, FIG. 2 is used to show these same components (i.e., the components that are part of the wound incubator 1 ) enclosed in a wound incubation device 23 . This wound incubation device 23 contains a filtered air intake 2 and an outlet connection 25 for connection to the wound dressing 18 via the delivery tubing 15 . The face of this device 23 may be used to mount operational controls and display desired information.
[0038] Because of the fear of possible contamination, all components touched by the water are typically designed for single patient use like those used in respiratory humidifiers. The wound incubator may be configured to be mounted on an IV pole or on a bed rail, placed on a bedside table or designed to be portable. It should be located close to the wound site. It uses an electrical power source from a battery or a 120V power cord. Temperature sensor 17 communicates with the wound incubation device 23 . The wound vacuum unit 22 may also be configured to communicate with the wound incubator.
[0039] Another embodiment would have the components of the wound incubator and the components of the vacuum source contained in a single enclosure. Both of these devices would not only share a single enclosure, they also would share a power supply, electronics, displays and communications. A single enclosure would save space, costs, and be simpler to hook up and operate. Dressing inlet and outlet tubes would go to the same device.
[0040] This wound warming method could be suitable for cooler than normal wounds and those where thermoregulatory vasoconstriction may be occurring. These wounds would include those on humans as well as warm-blooded animals. With animals, the dew point temperature used would correspond to that particular animal's normal body temperature.
[0041] It will be appreciated by those skilled in the art that while the invention has been described above in connection with particular embodiments and examples, the invention is not necessarily so limited, and that numerous other embodiments, examples, uses, modifications and departures from the embodiments, examples and uses are intended to be encompassed by the claims attached hereto. | A method of treating a wound by restoring a bodies' physiological norms is disclosed. A wound dressing is applied over the wound in which the wound dressing has an inlet and an outlet and furthermore forms a substantially airtight cover over the wound. A vapor is supplied to the wound dressing via the inlet. The wound is warmed by condensing the vapor into a condensate on a surface of the wound, thereby releasing a latent heat of vaporization and adding moisture to the wound. The excess condensate is removed from the wound dressing via the outlet. | 0 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of U.S. patent application Ser. No. 12/485,971 filed Jun. 17, 2009, the entire contents of which are being incorporated herein by reference.
BACKGROUND
My invention relates to a spray paint system that does not require the use of traditional organic based propellants in the paint mixture. My system uses an inverted or substantially vertical container where a paint formulation in liquid form occupies the lower section of the container and compressed air occupies an upper portion of the container above the paint mixture. Pressurizing the air in the space above the paint forces the paint out through a replaceable nozzle or tip that is attached to the lower end of the container. The spray paint system has a variety of uses all involving an inverted position relative to standard spray painting applications, such as marking objects, specifically making precise pin point markings, such as letters or symbols, on horizontal objects, such as roadways, buildings, walkways, etc. to assist construction or utility repair crews and the like.
Many spray paint systems are known and generally fall into two categories. The ubiquitous aerosol can of spray paint is well known. In this system a paint mixture and a propellant, typically an easily vaporized hydrocarbon or other organic based compound, are injected into the can under pressure. The paint and propellant are discharged through a valve attached to the top of the can when held in an upright orientation. Such systems only contain organic compounds as the propellant, which are mixed with the paint formulation. Once the propellant is exhausted from the can no more paint can be removed, thus making for a wasteful situation. Additionally, these aerosol spray paint cans are costly to manufacture, present a disposal problem, and typically use high cost hydrocarbon propellants that can be harmful to the environment.
The second known spray paint system is where a paint formulation is added directly to a rigid container at ambient pressure (no propellant mixed with the paint formulation). The container is then pressure sealed and a source of pressurized fluid, typically compressed air, is regulated through an inlet into the container causing the paint formulation to pressurize above atmospheric pressure. The container is held in an upright position and a trigger mechanism is activated so that pressurized paint is then forced out of the rigid container through an attached hose and then through a special spray nozzle with combined valve means that is designed to atomize the entrained paint particles. Such systems only operate in an upright position. A variant of this system uses a venturi to entrain paint in a high-pressure air stream.
My invention eliminates the disadvantages of these known spray paint systems through the use of an inverted spray paint system that can be pressurized using only air.
These and other advantages will be apparent from the following detailed discussion of my invention and the appended claims.
SUMMARY
My invention is an improved spray paint system that does not require the use of a traditional hydrocarbon propellant and instead uses an inverted elongated cylindrical container pressurized with air using a pump that is partially contained within the container. Specifically, one embodiment of my invention comprises, in combination, an inverted spray paint system having a rigid elongated container having an interior space, a first opening located at an upper end of the container and a second opening located at a lower end of the container. A paint mixture can be located in the interior space at the lower end of the interior space of the container. The lower end is defined as the end closest to the ground. The upper end of the interior space (opposite the lower end) contains a portion of a pumping device that sits above the paint mixture. The pumping means is used to pressurize the space above atmospheric pressure in order to force the paint formulation out through the second opening. The system also has at least one cap configured to releasably attach the pumping device to the upper end of the container and to allow introduction of a liquid paint mixture into the container. The system has a removable spray tip in fluid communication with the second opening of the rigid container that allows for egress of the paint mixture in a spray pattern upon activation of a trigger operably connected to the rigid container.
In yet another embodiment of my invention, a spray paint system is provided comprising, in combination, a rigid elongated container having an interior space, a first opening located at an upper end of the container and a second opening located at a lower end of the container. A frame that supports the elongated container has a frame handle located near the upper end of the elongated container to assist a user of the system to move the container while spray painting a horizontal surface. This embodiment also has a pumping device partially contained in the upper end of the interior space of the elongated container and has a pump handle connected to the pumping device configured to allow a user to manually activate the pumping device to pressurize the interior space to a pressure greater than atmospheric pressure. The frame has at least one wheel mounted to it near the lower end of the container to allow a user to roll the spray paint system along a horizontal surface during paint application. A removable spray tip in fluid communication with the second opening of the elongated container is configured to allow a pressurized paint formulation within the interior space to exit the elongated container in a spray pattern directed onto a horizontal surface as a user moves the painting system using the wheel. There also is a trigger positioned near the upper end of the elongated container that is operably connected to the container and is used to activate delivery of a pressurized paint mixture through the spray tip.
My invention can also be configured where the trigger is operably connected to the spray tip and preferably where the trigger is connected to a cable that is operably connected to a valve in the spray tip. In order to keep the spray paint system in a generally vertical position when not rolling or moving the system it is preferred to include a vertical stabilizer near the lower end of the container attached to either the frame, the container or to both. The pumping device is preferably a self-contained assembly that can be removed from the container and that has a handle accessible to a using for manually activating the pump. The pump can be connected to the container through the first opening in the upper end of the container. The spray paint system can also include a pressure indicator in fluid communication with the container to show the user the pressure level in the container. Likewise, the system can include a pressure relief valve in fluid communication with the container as a safety feature to prevent over pressuring of the system.
Regardless of the mechanical configuration of my spray paint system, an important aspect of my invention is that the only propellant used is compressed air. The system does not contain any volatile compounds, such as hydrocarbons.
Although a preferred pumping device is self-contained within the system of my invention, for example a hand pump, it can also be a completely external pumping means. In either case the pumping device is in communication with the first opening to create the pressurized air above the paint mixture. The pressure source can comprise any known means to generate a fluid under pressure, for example a pump or cylinder of compressed gas. If a pump is used, then it can be battery operated, similar in design to battery operated power tools, or it can be powered using a conventional AC power source.
My spray paint system is to be used only in a generally downward direction with the paint formulation being dispensed through a spray tip or nozzle located at the lower end of the container. Control of the paint flow is accomplished by controlling pressure within the elongated container, by opening and closing a valve in fluid communication with the spray tip, or a combination of both. A trigger or valve or other regulation means that is in fluid communication with the source of pressurized fluid or with the pressurized paint mixture can accomplish this. Increasing or maintaining a given pressure within the elongated container will work to continuously force the paint out through the discharge opening and the spray tip. Decreasing or stopping the pressure in the container will slow or stop the rate of paint flow.
BRIEF DESCRIPTION OF THE FIGURES
The advantages and features of the present invention will become better understood with reference to the following more detailed description and claims taken in conjunction with the accompanying drawings, in which like elements are identified with like symbols, and in which:
FIG. 1 is a schematic representation showing a side view of one embodiment of my invention;
FIG. 2 is a schematic representation showing a front view of the embodiment illustrated in FIG. 1 ;
FIG. 3 is a schematic representation of one embodiment of a self-contained hand pump that can be inserted into the elongated cylinder of my invention;
FIG. 4 is a schematic representation showing a front view of a second of one embodiment of my invention; and
FIG. 5 is a schematic representation of another embodiment of my invention.
DETAILED DESCRIPTION
Referring now to FIGS. 1-2 , which shows just one of many possible configurations, sizes, and shapes of the elongated container 1 of my spray paint system, the container is preferably fabricated from any material of construction that can withstand pressures greater than atmospheric, preferably in the range of from about 20 psig to about 120 psig. Rigid plastics, glass, metal or like materials will all be acceptable. Container 1 has an interior space, a first opening 2 and a second opening 3 . The upper end 20 of the interior space accepts or receives pumping device 11 (see FIG. 3 ), which includes a hand pump 12 that is used to manually operate the pump to pressurize the interior space above atmospheric pressure. As the pump handle is stroked by a user air is forced into the upper section of the interior space and subject to compressive forces, which continually increases the pressure in the upper end of the container.
The container also has a lower end 21 that holds a liquid paint mixture added through opening 2 . First opening 2 is configured to allow the pump device to be placed in the interior of rigid container 1 and then sealed within using cap 13 . Cap 13 is removable to allow removal of the pump and access to the interior space of the container. Cap 13 can connect with container 1 through connection means, which can be any known type of connection that will maintain applied pressure to the interior of container 1 , for example, screw threads, snap lock, bayonet fitting, snap lock released through threads, claps, and the like connections. Second opening 3 allows a pressurized fluid, such as compressed air, nitrogen, carbon dioxide, and the like, to be introduced to the interior of container 1 . Optionally, container 1 may have a relief valve 14 (see FIG. 4 ) secure in opening 14 ′ to vent excess pressurized fluid from the interior if an over-pressurization occurs. Additionally, the container may have a pressure gauge 15 secure in opening 15 ′ to allow the user to monitor the pressure within the container.
When the air in the upper end of the interior of the rigid container is pressurized, which creates a force exerted on the paint mixture that will cause it to exit the lower end of the container through discharge or second opening 3 . To control the discharge or spray pattern of the exiting paint, a spray tip or nozzle 4 is connected to discharge opening 3 . Preferably tip 4 is removable and can also be disposable. One possible design includes a nozzle 4 that is capable of accepting a tip insert (not shown) to allow for very fine painting of numbers and letters. The insert can be releasably connected to the spray nozzle through any connection type known to the art provided that the insert can be disconnected and re-connected without damaging the insert or the spray nozzle 4 . Preferred connections would include a screw fitting, snap-lock, press fit, luer-lock, bayonet, quick disconnect, or any other known releasable connector. For ease and speed of connection the most preferred connector is a press fit connection.
Although a specific type of pump is shown in the embodiment in the Figures the pump can also be configured as a battery or AC operated device or other pressure device, such as a small cylinder of compressed gas that can supply a pressurized fluid (air or other gas) through the first opening 2 or through another opening located in the upper end of the container. In some circumstances it may be convenient to design the pump to accept power in the form of DC current supplied by a cigarette lighter or other power connector now typically available in most automobiles, trucks or other vehicles. The spray paint system also comprises a frame 7 that holds or supports (both permanently or removably) container 1 . The frame can be composed of any structural material, such as plastic or metal that will adequately support the container. Preferably the frame has a handle 6 that allows the user to move the system along a horizontal surface using one or more wheels 5 attached to either the frame or the container.
The frame could also have one or more vertical stabilizers 10 to maintain the system in a substantially upright position when not being moved along a horizontal surface. The system also preferably has a trigger or actuator 8 to cause the paint to be sprayed through nozzle 4 . Preferably the trigger is located near the upper end of the container near the handle to allow convenient access to the user when pushing or pulling the system along a horizontal surface. Most preferably, the trigger is connected via cable 9 or other linkage to valve 16 in fluid communication with the interior space and the nozzle. Once the upper end of the interior space of the container has been pressurized with ambient air using the pumping device, the user will activate the trigger to open the valve to allow the paint to spray outward through the nozzle. The percentage opening of the valve dictates the flow rate of paint through the discharge opening of the container and spray tip.
Yet another possible embodiment of my invention is illustrate in FIG. 5 , where utility sprayer 40 comprises a pump assembly 47 mounted to a telescopic frame 51 through bracket 46 . The pump assembly comprises a reservoir that can withstand pressures up to 60 psig or higher and can be pressurized with ambient air using a hand pump 44 or alternatively through fitting 54 , such as a standard tire or inner tube fitting, using any compressed gas source, such as a compressed gas cylinder or air compressor. Pressure gauge 43 is used to monitor the pressure in pump 47 . The telescoping frame 51 is released by pushing button or release mechanism 56 . Once button 56 is pushed, frame 51 can be extended to increase the distance between wheel 52 and handle 41 to allow utility spray 40 to extend to a convenient operating length. In the fully extended configuration the sprayer 40 can be wheeled along a surface to be painted and in the fully collapsed configuration the sprayer can be held like a wand and easily pointed at the surface to be painted, without using wheel 52 . Snap features 45 can be used to lock the telescoping frame 51 at various predetermined lengths.
Pressure hose 49 connects the pressure reservoir of pump assembly 47 with a paint bottle 48 through connector or cap 57 . Paint bottle 48 also has a second connector 58 to accept nozzle 53 or spare nozzles 55 . Preferably, connectors 57 and 58 are non-standard in that they are coded specifically for utility sprayer 40 such that only pressure hose 49 and nozzles 53 and 55 can be connected. Paint bottle 48 may hold any paint composition directly and may be constructed of materials such that it is biodegradable upon disposal. Alternatively, a collapsible pouch or bag of paint maybe inserted into the bottle that can easily be discarded when empty, thus eliminating clean up of the bottle. Preferably the pouch is biodegradable.
Trigger 42 is operably connected to cable 50 and operates a valve 59 associated, or in fluid connection, with nozzle 53 . Squeezing trigger 42 opens valve 59 and allows pressurized paint from bottle 48 to flow out of nozzle 53 . Nozzles 53 and 55 can be adjustable to vary the spray pattern from a wide to a tight angle depending on the application and surface to be painted. Preferably the frame, pump assembly and paint bottle/nozzle assembly are configured so that these three assemblies are modular or otherwise each easily removable from the utility sprayer such that one or more malfunctioning assembly can be replaced with a new or otherwise operating assembly.
It is important that the elongated container or paint bottle is positioned in an inverted and vertical position so the paint formulation can be sprayed onto horizontal objects, especially those located on or near ground level. My invention can be used to mark objects such as roadways, walkways, yards, buildings or other structures for construction, survey, safety, or the like purposes.
The invention has been described with reference to a preferred embodiment. Obviously, modifications and alterations will occur to others upon reading and understanding the preceding specification. It is intended that the invention be construed as including all such alterations and modifications insofar as they come within the scope of the appended claims or the equivalents thereof. | A spray paint system for spraying a horizontal surface having a frame supporting an inverted elongated rigid container configured to hold a paint formulation that is pressurized with a pumping device partially located within the container where the frame has at least one wheel to allow a user to roll the system along a horizontal surface while spraying paint through a removable spray tip. This system can be used to mark a horizontal surface with precise and clear writing of lines, letters or symbols. | 1 |
BACKGROUND OF THE INVENTION
Production declines in oil reservoirs take place as a result of depletion and/or damages by organic and inorganic species deposition (formation surface deposition, pore throat plugging, and re-entrainment into reservoir's fluids). The deposition of organic and inorganic species can be attributed to: (1) asphaltenes; (2) heavy paraffins; (3) carboxylate scale, carbonate scale, sulfate scale, or combinations of such scale in the forms of alkaline cations; and (4) finely dispersed clays particles (e.g., kaolinite, illite, smectite, or combinations) through perforation tunnels and gravel packs.
The pore throat diameter in oil reservoirs varies from 1 to 11 μm. Sandstone oil reservoirs, in particular, tend to be homogeneous with low permeability and porosity contrasts in any given single interval. Once precipitates or fine particles deposited within pores, they can not be extracted back into the reservoir by stimulation treatment. However, they can be pierced through into the other side of the plugged pores. The success of re-perforation in oil reservoirs is usually limited or short lived.
Depletion and asphaltenes precipitation in oil reservoirs can be averted by injecting, for instance, saline water to increase the reservoir's pressure above the saturation pressure and thus enhance oil recovery and prevent asphaltenes precipitation. Paraffins precipitation unlikely takes place if the reservoir's temperature is higher than the paraffins' cloud point temperatures.
Possible sources of saline water for injection operations in oil reservoirs include, for instance, aquifers saline water or oil-fields produced water. However, aquifers water could cause fine clays deposition depending on their formation rock while oil-fields produced water tend to cause at least calcium carboxylate and/or calcium carbonate scale deposition. Insufficient quantities and/or unacceptable qualities of each standalone source of saline water are always problematic in injection operations. Thus, such sources of saline water are most likely blended to sufficiently fill the reservoir voidage and fulfill the pressure support requirement.
The quality of saline water as strictly measured by its oil content and total suspended solids (TSS) is of significant importance since poor quality leads to injectivity reduction and wells plugging. The general parameters guidelines for the required quality of saline water to be injected in oil reservoirs are not to exceed: (1) 50 mg/L of oil content; and (2) 10 mg/L of TSS with 10 μm of particle size. Although providing meaningful parameters guidelines is important, however, such guidelines could obscure significant fundamental issues. Such issues could render saline water injection very expensive operations and cause irreversible reservoir damages.
True understanding of the nature and specific requirements for a given oil reservoir along with the chemistry of the designated saline water are a must for successful injection operations. Thus, this invention presents innovative and off the beaten path methods to provide an acceptable quality of saline water that is: (1) actually needed to steadily enhance oil production; and (2) technically and economically achievable.
SUMMARY OF THE INVENTION
In one aspect, the present invention provides a method for blending oil-fields produced water with saline water to produce at least a nearly free saline stream of carboxylates and suspended particles. The inventive method comprises the steps of: (a) increasing the pH of oil-fields produced water by adding an amine solvent to increase the dissociation of carboxylates; (b) mixing the pH increased oil-fields produced water with saline water to produce intermediate saline stream and dispersed oily droplets by bonding carboxylates in the pH increased oil-fields produced water with suspended particles in saline water; (c) separating the dispersed oily droplets from the intermediate saline stream by hydrophobic membranes to produce nearly free saline stream of carboxylates and suspended particles; (d) removing the amine solvent and oxygen from the nearly free saline stream of carboxylates and suspended particles by a vacuum-based unit; and (e) injecting the nearly free saline stream of carboxylates and suspended particles into subterranean formation for hydrocarbons recovery. Saline water is aquifer water, seawater, or a combination thereof. The amine solvent is selected from the group consisting of isopropylamine, propylamine, dipropylamine, diisopropylamine, ethylamine, diethylamine, methylamine, dimethylamine, or a combination thereof. The vacuum-based unit is vacuum membrane distillation, vacuum distillation, vacuum deaerator, or a combination thereof.
In another aspect, the present invention provides a method for blending oil-fields produced water with saline water to produce at least a nearly free saline stream of carboxylates and suspended particles. The inventive method comprises the steps of: (a) mixing oil-fields produced water with saline water to form intermediate saline stream and dispersed oily droplets by bonding carboxylates in oil-fields produced with suspended particles in saline water; (b) separating the dispersed oily droplets from the intermediate saline stream by hydrophobic membranes to produce nearly free saline stream of carboxylates and suspended particles; (c) removing oxygen from the nearly free saline stream of carboxylates and suspended particles by a vacuum-based unit; and (d) injecting the nearly free saline stream of carboxylates and suspended particles into subterranean formation for hydrocarbons recovery. Saline water is aquifer water, seawater, or a combination thereof. The vacuum-based unit is vacuum membrane distillation, vacuum distillation, vacuum deaerator, or a combination thereof.
In yet another aspect, the present invention provides a method for removing carboxylic acids from an aqueous stream to produce at least a nearly free aqueous stream of carboxylic acids. The inventive method comprises the steps of: (a) increasing the pH of the aqueous stream by adding an amine solvent to produce an intermediate aqueous stream and enhance the dissociation of carboxylic acids; (b) separating carboxylic acids from the intermediate aqueous stream by hydrophobic membranes to produce nearly free aqueous stream of carboxylic acids; (c) removing the amine solvent and oxygen from the nearly free aqueous stream of carboxylic acids by a vacuum-based unit; and (d) injecting the nearly free aqueous stream of carboxylic acids into subterranean formation for hydrocarbons recovery. The aqueous stream is oil-fields produced water or industrial by-product water. The amine solvent is selected from the group consisting of isopropylamine, propylamine, dipropylamine, diisopropylamine, ethylamine, diethylamine, methylamine, dimethylamine, or a combination thereof. The vacuum-based unit is vacuum membrane distillation, vacuum distillation, vacuum deaerator, or a combination thereof.
In yet another aspect, the present invention provides a method for removing carboxylic acids from an aqueous stream to produce at least a nearly free aqueous stream of carboxylic acids. The inventive method comprises the steps of (a) separating dissolved and naturally dissociated carboxylic acids from the aqueous stream by hydrophobic membranes to produce nearly free aqueous stream of carboxylic acids; (b) removing oxygen from the nearly free aqueous stream of carboxylic acids by a vacuum-based unit; and (c) injecting the nearly free aqueous stream of carboxylic acids into subterranean formation for hydrocarbons recovery. The aqueous stream is oil-fields produced water or industrial by-product water. The vacuum-based unit is a vacuum membrane distillation, vacuum distillation, vacuum deaerator, or a combination thereof.
This invention is not restricted to use in connection with one particular application or industry. Further objects, novel features, and advantages of the present invention will be apparent to those skilled in the art upon examining the accompanying drawings and upon reading the following description of the preferred embodiments, or may be learned by practice of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a possible flow diagram for blending and treating oil-fields produced water and aquifers saline water for oil reservoirs injection operations.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Aquifers Saline Water
The nature of the suspended particles as related to the formation of the aquifer water source is very important in selecting the source of aquifer water. This is the parameter that the planners of the saline water injection project should be focused on. The oil content is totally insignificant since aquifers water is almost always free of oil content.
Clays exist in any formation and their portions depend on the formation type. For instance, clays constitute significant portions (e.g., >40%) of the total mineralogy in sandstone formation. Clay particles are aluminosilicates that contain water trapped between the silicate sheets. They can be divided into at least three major groups: (1) kaolinites with a general structure of Al 2 Si 2 O 5 (OH) 4 ; (2) smectites with a general structure of (Ca, Na, H)(Al, Mg, Fe, Zn) 2 (Si, Al) 4 O 10 (OH) 2 -xH 2 O; and (3) illites with a general structure of (K, H)Al 2 (Si, Al) 4 O 10 (OH) 2 -xH 2 O. The xH 2 O term in the smectites and illites represents the variable water content that members of these groups could contain. Such groups of clays are chemically and structurally analogous to the kaolinites group except they contain varying amounts of water that allow more substitution of their cations.
The physical characteristics of clays are very important since they: (1) form microns and sub-microns particles (an important factor in saline water injection); (2) can absorb or lose water from simple humidity or temperature or salinity changes; (3) often swell when water with incompatible salinity is absorbed as the water fills the spaces between the stacked silicate layers (another important factor in saline water injection); and (4) are rarely found separately and usually are mixed not only with other clays but also with sub-microns particles of quartz, feldspars, and carbonates (due to dissociation of their hydroxyl groups).
Finely dispersed clay's particles (e.g., 0.01 to 0.1 μm) are very critical since the attractive forces between them are considerably less than the repelling forces of their electric charges. Thus, they are nearly immune to any traditional water treatment steps such as coagulation, flocculation and filtration. If such dispersed clay's particles are kept in the aquifers water without removal or further dispersion or sufficient stabilization before injection, they are destined to cause blockages or plugging at the pore throats of the oil reservoir. The resultant decline in permeability can severely impair the productivity of oil wells. The typical acid treatment in sandstone oil reservoirs, for example, is very complex to reverse clays plugging and the global success rate of such a treatment is very discouraging (<30%).
Oil-Fields Produced Water
Oil content and TSS are critical in oil-fields produced water since: (1) dispersed and dissolved oil residues remain in produced water; (2) produced water is collected from different gathering centers and potential incompatibility would affect the TSS of the gathered produced water.
Accurate and complete oil content measurements, in particular, are very crucial. The oil content in produced water consists of three portions: (1) the dispersed (or floating) insoluble oil droplets on the produced water surface; (2) the dissolved non-polar hydrocarbons (species that are strictly composed of hydrogen-carbon chains and known as Total Petroleum Hydrocarbons or TPH); and (3) the dissolved organic non-hydrocarbons that consist of mainly oxygen-containing species and known as carboxylic or fatty or naphthenic acids. It should be pointed out that the dissolved species are mostly sparingly water soluble species. However, they remain dissolved in produced water because they are below their aqueous solubility limits and the hyper salinity of produced water tends to slightly increase their limited aqueous solubilities.
Oxygen compounds such as carboxylic acids in crude oil exist within their higher molecular weights, sparingly water soluble and nonvolatile hydrocarbons (e.g., heavy n-paraffins, cyclo- and dicyclo-paraffins, ploynucleiaromatics etc.). As such, the carbon structures of carboxylic acids typically correspond with the structures of hydrocarbons that co-exist with. For instance, medium- to long-: (1) straight chain aliphatic carboxylic acids are predominant in heavy n-paraffins crude; (2) monocyclic and dicyclic carboxylic acids are predominant in cyclo- and dicyclo-paraffins; and (3) aromatic carboxylic acids are predominant in ploynucleiaromatics. Such higher-molecular weight carboxylic acids are sparingly soluble in water (similar to their counter hydrocarbons).
However, a portion of medium- to higher-molecular weight carboxylic acids in downhole reservoirs conditions can be hydrolyzed and/or thermally decomposed to lower-molecular weight carboxylic acids. As such, reservoirs' brine regardless of their hydrocarbons natures, contain low molecular weights and water miscible carboxylic acids (e.g., formic, acetic, propionic, and butyric acids). The highest concentrations of such acids tend to be in downhole brine at 80-100° C.
Most of the reported oil content measurements in oil-fields produced water are based on the “dispersive infrared measurements” and thus they are limited to the determination of only the dissolved Total Petroleum Hydrocarbons (TPH). As such, the dispersed oil and carboxylic acids portions are typically not included in the reported oil content measurements. To properly evaluate oil-fields produced water for oil reservoirs injection operations, however, the quantifications of such missing oil portions must be included.
The determination, in particular, of carboxylic acids in oil-fields produced water is of a significant importance. At a pH value of 6.5, as is the case with most oil-fields produced water at the surface, reactive carboxylic acids with molecular weights between 150 and 350 exist in produced water. Such carboxylic acids contain the carboxylate (naphthenate) RCOO − anions, and thus they are negatively charged. Depending on their structural identities, concentrations and dissociation in produced water as a function of pH values, they pair with positively charged species. Cations such as sodium and calcium can therefore form sodium or calcium carboxylate precipitates (known as soaps).
As carbon dioxide and other acid gases are vented from the processing of wet crude oil at the surface, the pH values of the segregated produced water from the wet crude oil would increase. The result is the potential precipitation of mixed calcium carbonate/calcium carboxylate along with the formation carboxylate emulsion (surface active species). Once produced water is re-injected for pressure support, the downhole pH of the newly mixed fluid media in the reservoir would decrease, and thus bicarbonate serves as a buffer which would enhance the generation of carboxylate anions. The carbonate-carboxylate interactions are depicted as follows:
In the case of sandstone oil reservoirs, the ionic charge (zeta potential) on sandstone formation surfaces generally varies as follows: positive at pH values below 4-5; neutral at the pH value of 4-5; and negative at pH values above 4-5. However, downhole brine in most oil reservoirs is generally rich with sodium-calcium chloride, and the sufficient presence of the calcium ion in the brine could positively change the ionic charge of sandstone formation surfaces above the 4-5 pH values. This is attributed to the classical charge reversal brought on by the adsorption of divalent ions (e.g., calcium) of opposite charge to the sandstone formation surfaces (e.g., quartz and clays).
In the case of carbonate oil reservoirs, the ionic charge on calcite formation surfaces varies as follows: positive at pH values below 8.3; neutral at the pH value of 8.3; and negative at pH values above 8.3. The ionic charges on dolomite and magnesite formation surfaces behave nearly similarly to calcite formation surfaces: positive at pH values below 7-8; neutral at the pH values 7-8; and negative at pH values above 7-8.
Since the generated carboxylates are negatively charged (anions), and sandstone as well as carbonate formation surfaces are positively charged at the typical downhole pH values (4.0 to 5.5), such carboxylates adsorb on the sandstone or carbonate formation matrix surfaces to comprise deposits of organic acid coatings. Such deposits can be further strengthened by the presence, for instance, of heavy hydrocarbons and asphaltenes. If such carboxylates are kept in produced water without removal before injection, they are destined to plug the formation matrix of the oil reservoir.
Blending Aquifers Saline Water with Oil-Fields Produced Water
As explained above, clays are intercalation minerals that form layered structures of aluminosilicates or ions-aluminosilicates with hydroxyl groups. For instance, kaolinite (Al 2 Si 2 O 5 (OH) 4 ) is a two-layer aluminosilicate clay consisting of alternating silica and alumina with hydroxyl groups at the particle edge. Carboxylic acids can form reactive (ester) linkage through their carboxylate (RCOOH) groups to the hydroxyl groups (R″OH) on the clay particles (acid-base reaction). My solution is thus innovatively centered on bonding the finely dispersed clay's particles in aquifers water with carboxylic acids in produced water and then separated them as organic (oily) coated droplets or layers from the blended saline water using hydrophobic membranes. As such, carboxylates in produced water serve as an adsorption sink for the finely dispersed clay's particles in aquifers water.
To nearly completely dissociate carboxylic acids in produced water to enhance their adsorption to sub-microns suspended clays particles, the pH of produced water should be increased. The higher the pH value, the higher the carboxylates concentrations. Several solvents have been identified for potential use to increase the pH values of produced water. These solvents are isopropylamine (IPA), ethylamine (EA), propylamine (PA), dipropylamine (DPA), diisopropylamine (DIPA), diethylamine (DEA), and dimethylamine (DMA). However, IPA is the preferred solvent for pH adjustment. The preference of IPA is attributed to its favorable properties (boiling point: 32.4° C.; vapor pressure: 478 mmHg at 20° C.) that would allow it's near complete recovery as well as its minimal environmental risks.
The membrane concept takes advantages of the facts that dispersed organic (oily) droplets and water are immiscible, and a properly configured hydrophobic membrane would efficiently repel water. As such, the oily coated droplets (the membrane wetting species) can permeate through the hydrophobic membrane by applying a very low pressure while water (the non-wetting liquid) is repelled by the membrane hydrophobicity.
Reference is now made to FIG. 1 , which depicts a simplified possible flow diagram illustrating the blending of oil-fields produced water and aquifer saline water to bond carboxylates with suspended particles and then separate such bonded species as oily droplets from the blended saline stream. The pH value of a pre-filtered oil-field produced water stream [ 10 ] will be adjusted by adding an amine solvent [ 12 ] to nearly completely dissociate carboxylic acids before blending with a pre-filtered aquifer saline stream [ 14 ]. The blended saline stream [ 16 ] will then be fed to a stage of hydrophobic membranes [ 18 ] to recover the carboxylates-coated suspended particles as oily droplets [ 20 ] from the saline stream [ 22 ]. After that, the saline stream [ 22 ] will be delivered to preferably another stage of hydrophobic membranes [ 24 ] that serves as a vacuum membranes distillation unit to recover the amine solvent [ 26 ] from the treated saline water [ 28 ]. The vacuum membranes distillation unit [ 24 ] can serve dual purposes by also removing oxygen from the treated saline stream. The recovered amine solvent [ 26 ] will be condensed and reused while the treated saline stream [ 28 ] will be injected in oil reservoirs. It should be pointed out that the step of adding an amine solvent [ 12 ] can be eliminated if the pH adjustment is not essential, and thus the vacuum membranes distillation unit [ 24 ] will only be used to deplete oxygen from the treated saline stream. It should also be pointed out that the vacuum membranes distillation unit [ 24 ] can be replaced with other appropriate units (e.g., vacuum deaerator, vacuum distillation or pervaporation) for the recovery of the amine solvent and/or the depletion of oxygen.
It should be understood that this invention can be used for blending oil-fields produced water with seawater instead of aquifers saline water to bond carboxylates in produced water with suspended particles in seawater.
It should also be understood that this invention can be used for the removal of carboxylic acids and other oily species from only oil-fields produced water without blending with aquifers saline water to be injected in oil reservoirs or to meet environmental regulations or any other purposes.
It should also be understood that this invention can be used for the removal carboxylic acids including water miscible acids (such as acetic, formic, acetic, propionic and butyric acids) from aqueous streams (e.g., industrial by-product water) other than oil-fields produced water.
It should also be understood that the identified amine solvents in this invention can be used as effective dispersants to lift heavy wet crude oil emulsions from downhole and/or to transport such emulsions via pipelines. | This invention presents innovative and off the beaten path methods to mainly produce suitable saline streams for oil-fields water injection operations. The production of such suitable saline streams can: (1) be achieved economically; and (2) meet the actual stringent requirements for injection operations to steadily enhance oil production from depleted and plugged wells. | 4 |
PRIORITY OF INVENTION
[0001] This application claims priority under 35 U.S.C. 119(e) from U.S. Provisional Patent Application No. 60/971,395, filed 11 Sep. 2007, the contents of which are incorporated herein in their entirety.
BACKGROUND OF THE INVENTION
[0002] International Patent Application Publication Number WO 2004/046115 provides certain 4-oxoquinolone compounds that are useful as HIV integrase inhibitors. The compounds are reported to be useful as anti-HIV agents.
[0003] International Patent Application Publication Number WO 2005/113508 provides certain specific crystalline forms of one of these 4-oxoquinolone compounds, 6-(3-chloro-2-fluorobenzyl)-1-[(S)-1-hydroxymethyl-2-methylpropyl]-7-methoxy-4-oxo-1,4-dihydroquinolone-3-carboxylic acid. The specific crystalline forms are reported to have superior physical and chemical stability compared to other physical forms of the compound.
[0004] There is currently a need for improved methods for preparing the 4-oxoquinolone compounds reported in International Patent Application Publication Number WO 2004/046115 and in International Patent Application Publication Number WO 2005/113508. In particular, there is a need for new synthetic methods that are simpler or less expensive to carry out, that provide an increased yield, or that eliminate the use of toxic or costly reagents.
SUMMARY OF THE INVENTION
[0005] The present invention provides new synthetic processes and synthetic intermediates that are useful for preparing the 4-oxoquinolone compounds reported in International Patent Application Publication Number WO 2004/046115 and in International Patent Application Publication Number WO 2005/113508.
[0006] Accordingly, in one embodiment, the present invention provides a method for preparing a compound of formula 10
[0000]
[0000] or a pharmaceutically acceptable salt thereof, in which a compound of formula 4
[0000]
[0000] or a salt thereof is prepared and converted into a compound of formula 10, characterized in that the compound of formula 4 is prepared from a compound of formula 15
[0000]
[0000] or a salt thereof, by the steps of replacing the bromine atom with a carboxyl group, and replacing the hydroxyl group with a hydrogen atom.
[0007] In another embodiment the invention provides a compound of formula 15:
[0000]
[0000] or a salt thereof.
[0008] In another embodiment the invention provides a method for preparing a compound of formula 15:
[0000]
[0000] or a salt thereof comprising converting a corresponding compound of formula 14:
[0000]
[0000] to the compound of formula 15 or the salt thereof.
[0009] In another embodiment the invention provides a compound of formula 15a:
[0000]
[0000] that is useful as an intermediate for preparing the 4-oxoquinone compounds.
[0010] In another embodiment the invention provides a compound of formula 16:
[0000]
[0000] that is useful as an intermediate for preparing the 4-oxoquinone compounds.
[0011] The invention also provides other synthetic processes and synthetic intermediates disclosed herein that are useful for preparing the 4-oxoquinone compounds.
DETAILED DESCRIPTION
[0012] The following definitions are used, unless otherwise described: halo is fluoro, chloro, bromo, or iodo. Alkyl denotes both straight and branched groups, but reference to an individual radical such as propyl embraces only the straight chain radical, a branched chain isomer such as isopropyl being specifically referred to.
[0013] It will be appreciated by those skilled in the art that a compound having a chiral center may exist in and be isolated in optically active and racemic forms. Some compounds may exhibit polymorphism. It is to be understood that the present invention encompasses processes for preparing any racemic, optically-active, polymorphic, tautomeric, or stereoisomeric form, or mixtures thereof, of a compound described herein, it being well known in the art how to prepare optically active forms (for example, by resolution of the racemic form by recrystallization techniques, by synthesis from optically-active starting materials, by chiral synthesis, or by chromatographic separation using a chiral stationary phase).
[0014] Specific and preferred values listed below for radicals, substituents, and ranges, are for illustration only; they do not exclude other defined values or other values within defined ranges for the radicals and substituents.
[0015] Specifically, C 1 -C 6 alkyl can be methyl, ethyl, propyl, isopropyl, butyl, iso-butyl, sec-butyl, pentyl, 3-pentyl, or hexyl.
[0016] A specific value for R a is methyl.
[0017] A specific value for R b is methyl.
[0018] A specific value for R c is 1-imidazolyl.
[0019] A specific value for R is ethyl.
[0020] In one embodiment, the compound of formula 4 or a salt thereof is prepared by metalating the compound of formula 15 or a salt thereof and treating with carbon dioxide to provide the compound of formula 3:
[0000]
[0000] or a salt thereof, and then converting the compound of formula 3 into a compound of formula 4.
[0021] The compound of formula 15 or a salt thereof may be, for example, a salt of formula 15a
[0000]
[0022] In another embodiment, the compound of formula 15 is converted into a compound of formula 16
[0000]
[0000] which is then metalated and treated with carbon dioxide to afford a compound of formula 4.
[0023] It will be appreciated that the step of replacing the bromine atom with a carboxyl group is a carboxylation. This step may conveniently be effected by metalation, for example, by treatment with isopropylmagnesium chloride or isopropylmagnesium chloride lithium chloride complex, followed by treatment with carbon dioxide.
[0024] It will also be appreciated that the step of replacing the hydroxyl group with a hydrogen atom is a dehydroxylation. This step may be effected by treatment with a trialkylsilane, such as triethylsilane, conveniently in the presence of trifluoroacetic acid.
[0025] In another embodiment of the invention the compound of formula 15 or a salt thereof is converted to a compound of formula 3:
[0000]
[0000] or a salt thereof. For example, the compound of formula 15 or a salt thereof can be converted to the compound of formula 3 or a salt thereof by metalating the compound of formula 15 or the salt thereof (e.g. by treatment with isopropylmagnesium chloride) and treating with carbon dioxide to provide the compound of formula 3 or the salt thereof.
[0026] In another embodiment of the invention the compound of formula 3 or the salt thereof is converted to a compound of formula 4:
[0000]
[0000] or a salt thereof.
[0027] In another embodiment of the invention the compound of formula 4 is converted to a compound of formula 5′:
[0000]
[0000] or a salt thereof, wherein R c is a leaving group (such as halo or 1-imidazolyl). The carboxylic acid functional group of Compound 4 can be converted to an activated species, for example an acid chloride or an acyl imidazolide (Compound 5′) by treatment with a suitable reagent, such as, for example, thionyl chloride, oxalyl chloride, cyanuric chloride or 1,1′-carbonyldiimidazole in a suitable solvent (e.g., toluene or tetrahydrofuran). Any suitable leaving group R c can be incorporated into the molecule, provided the compound of formula 5′ can be subsequently converted to a compound of formula 6. The reaction can conveniently be carried out using about 1 equivalent of 1,1′-carbonyldiimidazole in tetrahydrofuran. In one embodiment, the compound of formula 5′ is a compound of formula 5a.
[0000]
[0000] The compound of formula 4 may be converted to the compound of formula 5a by treatment with 1,1′-carbonyldiimidazole.
[0028] In another embodiment of the invention a compound of formula 5′ or a salt thereof, can be converted to a compound of formula 6:
[0000]
[0000] or a salt thereof, wherein R is C 1 -C 6 alkyl. In one embodiment, the compound of formula 5′ is converted to the compound of formula 6 by treatment with the corresponding mono-alkylmalonate salt. An example of a mono-alkylmalonate salt is potassium monoethylmalonate. For example, a compound of formula 5′ can be combined with about 1 to 5 equivalents of a monoalkyl malonate salt and about 1 to 5 equivalents of a magnesium salt in a suitable solvent. Conveniently, a compound of formula 5′ can be combined with about 1.7 equivalents of potassium monoethyl malonate and about 1.5 equivalents of magnesium chloride. A suitable base, for example triethylamine or imidazole, can be added to the reaction. The reaction can conveniently be carried out at an elevated temperature (e.g., about 100±50° C.) and monitored for completion by any suitable technique (e.g., by HPLC). Upon completion of the reaction, Compound 6 can be isolated using any suitable technique (e.g., by chromatography or crystallization).
[0029] In another embodiment of the invention the compound of formula 6 or a salt thereof, can be converted to a corresponding compound of formula 7:
[0000]
[0000] wherein R a and R b are each independently C 1 -C 6 alkyl; and R is C 1 -C 6 alkyl. Compound 6 can be converted to an activated alkylidene analog, such as Compound 7, by treatment with a formate group donor such as a dimethylformamide dialkyl acetal (e.g., dimethylformamide dimethyl acetal) or a trialkylorthoformate. The reaction can be carried out at elevated temperature (e.g., about 100±50° C.). This reaction may be accelerated by the addition of an acid catalyst, such as, for example, an alkanoic acid, a benzoic acid, a sulfonic acid or a mineral acid. About 500 ppm to 1% acetic acid can conveniently be used. The progress of the reaction can be monitored by any suitable technique (e.g., by HPLC). Compound 7 can be isolated or it can be used directly to prepare a compound of formula 8 as described below.
[0030] In another embodiment of the invention the compound of formula 7 can be converted to a corresponding compound of formula 8:
[0000]
[0000] wherein R is C 1 -C 6 alkyl. Compound 7 can be combined with (S)-2-amino-3-methyl-1-butanol (S-Valinol, about 1.1 equivalents) to provide compound 8. The progress of the reaction can be monitored by any suitable technique (e.g., by HPLC). The compound of formula 8 can be isolated or used directly to prepare a compound of formula 9 as described below.
[0031] In another embodiment, the invention provides a method for preparing a compound of formula 9:
[0000]
[0000] wherein R is C 1 -C 6 alkyl, comprising cyclizing a corresponding compound of formula 8:
[0000]
[0000] Compound 8 can be cyclized to provide Compound 9 by treatment with a silylating reagent (e.g., N, 0-bis(trimethylsilyl)acetamide, N,O-bis(trimethylsilyl)trifluoroacetamide or hexamethyldisilazane). The reaction can be conducted in a polar aprotic solvent (e.g., dimethylformamide, dimethylacetamide, N-methylpyrrolidinone or acetonitrile). A salt (e.g., potassium chloride, lithium chloride, sodium chloride or magnesium chloride) can be added to accelerate the reaction. Typically, about 0.5 equivalents of a salt such as potassium chloride is added. The reaction may be conducted at elevated temperature (e.g., a temperature of about 100±20° C.) if necessary to obtain a convenient reaction time. The progress of the reaction can be monitored by any suitable technique (e.g., by HPLC). During the workup, an acid can be used to hydrolyze any silyl ethers that form due to reaction of the silylating reagent with the alcohol moiety of compound 8. Typical acids include mineral acids, sulfonic acids, or alkanoic acids. One specific acid that can be used is aqueous hydrochloric acid. Upon completion of the hydrolysis, Compound 9 can be isolated by any suitable method (e.g., by chromatography or by crystallization). In the above conversion, the silating reagent transiently protects the alcohol and is subsequently removed. This eliminates the need for separate protection and deprotection steps, thereby increasing the efficiency of the conversion.
[0032] In another embodiment of the invention the compound of formula 9 is converted to a compound of formula 10:
[0000]
[0000] Compound 9 can be converted to Compound 10 by treatment with a suitable base (e.g., potassium hydroxide, sodium hydroxide or lithium hydroxide). For example, about 1.3 equivalents of potassium hydroxide can conveniently be used. This reaction may be conducted in any suitable solvent, such as, for example, tetrahydrofuran, methanol, ethanol or isopropanol, or a mixture thereof. The solvent can also include water. A mixture of isopropanol and water can conveniently be used. The progress of the reaction can be monitored by any suitable technique (e.g., by HPLC). The initially formed carboxylate salt can be neutralized by treatment with an acid (e.g., hydrochloric acid or acetic acid). For example, about 1.5 equivalents of acetic acid can conveniently be used. Following neutralization, Compound 10 can be isolated using any suitable technique (e.g., by chromatography or crystallization).
[0033] In another embodiment of the invention the compound of formula 10 can be crystallized by adding a seed crystal to a solution that comprises the compound of formula 10. International Patent Application Publication Number WO 2005/113508 provides certain specific crystalline forms of 6-(3-chloro-2-fluorobenzyl)-1-[(S)-1-hydroxymethyl-2-methylpropyl]-7-methoxy-4-oxo-1,4-dihydroquinolone-3-carboxylic acid. The entire contents of International Patent Application Publication Number WO 2005/113508 is incorporated herein by reference (in particular, see pages 12-62 therein). The specific crystalline forms are identified therein as Crystal Form II and Crystal Form III. Crystal form II has an X-ray powder diffraction pattern having characteristic diffraction peaks at diffraction angles 2θ(°) of 6.56, 13.20, 19.86, 20.84, 21.22, and 25.22 as measured by an X-ray powder diffractometer. Crystal form III has an X-ray powder diffraction pattern having characteristic diffraction peaks at diffraction angles 2θ(°) of 8.54, 14.02, 15.68, 17.06, 17.24, 24.16, and 25.74 as measured by an X-ray powder diffractometer. International Patent Application Publication Number WO 2005/113508 also describes how to prepare a crystalline form of 6-(3-chloro-2-fluorobenzyl)-1-[(S)-1-hydroxymethyl-2-methylpropyl]-7-methoxy-4-oxo-1,4-dihydroquinolone-3-carboxylic acid that have an extrapolated onset temperature of about 162.1° C., as well as how to prepare a seed crystal having a purity of crystal of not less than about 70%. Accordingly, seed crystals of 6-(3-chloro-2-fluorobenzyl)-1-[(S)-1-hydroxymethyl-2-methylpropyl]-7-methoxy-4-oxo-1,4-dihydroquinolone-3-carb oxylic acid can optionally be prepared as described in International Patent Application Publication Number WO 2005/113508. Advantageously, the process illustrated in Scheme I below provides a crude mixture of Compound 10 that can be directly crystallized to provide Crystal Form III without additional purification (e.g. without the prior formation of another polymorph such as Crystal Form II, or without some other form of prior purification), see Example 6 below.
[0034] In cases where compounds identified herein are sufficiently basic or acidic to form stable acid or base salts, the invention also provides salts of such compounds. Such salts may be useful as intermediates, for example, for purifying such compounds. Examples of useful salts include organic acid addition salts formed with acids, for example, tosylate, methanesulfonate, acetate, citrate, malonate, tartarate, succinate, benzoate, ascorbate, a-ketoglutarate, and a-glycerophosphate. Suitable inorganic salts may also be formed, including hydrochloride, sulfate, nitrate, bicarbonate, and carbonate salts.
[0035] Salts may be obtained using standard procedures well known in the art, for example by reacting a sufficiently basic compound such as an amine with a suitable acid affording an anion. Alkali metal (for example, sodium, potassium, or lithium) or alkaline earth metal (for example calcium or magnesium) salts of carboxylic acids, for example, can also be made.
[0036] The invention will now be illustrated by the following non-limiting Examples.
[0037] An integrase inhibitor of formula 10 can be prepared as illustrated in the following Scheme 1.
[0000]
Example 1
Preparation of Compound 3
[0038]
[0039] Compound 14 (10 g) was combined with 28 mL of THF and 9 mL of bisdimethylaminoethyl ether before being cooled to 0° C. Isopropylmagnesium chloride (22.9 mL of a 2.07 M solution in THF) was added and the mixture was allowed to warm to room temperature overnight. Additional isopropylmagnesium chloride (5 mL) was added to improve conversion before 3-chloro-2-fluorobenzaldehyde (4.4 mL) was added. After stirring at ambient temperature for 2 hours 38.6 g of a 14 wt % THF solution of isopropylmagnesium chloride lithium chloride complex was added. After stirring overnight at ambient temperature CO 2 gas was bubbled into the reaction mixture. When conversion was complete the reaction was quenched to pH<3 with 2 M hydrochloric acid. The phases were separated and the organic phase was extracted with ethyl acetate. The combined organic layers were washed with saturated aqueous sodium chloride. The organic phase was concentrated and the product precipitated by the addition of MTBE. The slurry was filtered and the product air dried to yield Compound 3: 1 H NMR (DMSO-d 6 , 400 MHz) δ 12.15 (br s, 1H), 7.81 (s, 1H), 7.42 (t, J=7.2 Hz, 1H), 7.26 (t, J=6.8 Hz, 1H), 7.15 (t, J=7.8 Hz, 1H), 6.77 (s, 1H), 6.09 (d, J=4.7 Hz, 1H), 5.90 (d, J=4.9 Hz, 1H), 3.84 (s, 3H), 3.80 (s, 3H).
Example 2
Preparation of Compound 4
[0040] Triethylsilane (6.83 g) was added to trifluoroacetic acid (33.13 g) that had been pre-cooled in an ice bath. Compound 3 (10 g) was added to the mixture keeping the temperature below 15° C. After stirring for 2 h MTBE was added to precipitate the product. The slurry was filtered and the product washed with additional MTBE. After drying, 9.12 g of Compound 4 was isolated: 1 H NMR (DMSO-d 6 , 400 MHz) δ 12.11 (br s, 1H), 7.47 (s, 1H), 7.42-7.38 (m, 1H), 7.14-7.08 (m, 2H), 6.67 (s, 1H), 3.87-3.84 (m, 8H).
[0041] Alternatively, Compound 4 can be prepared as follows.
[0042] Triethylsilane (7.50 g) was added to trifluoroacetic acid (49.02 g) that had been pre-cooled in an ice bath. Compound 3 (14.65 g) was added to the mixture keeping the temperature below 15° C. After stirring for 1 h a solution of 17.63 g sodium acetate in 147 mL methanol was added. The mixture was heated to reflux for 3 hours then cooled to 0° C. The slurry was filtered and the product washed with additional methanol. After drying 12.3 g of Compound 4 (89.7% yield) was isolated: 1 H NMR (DMSO-d 6 , 400 MHz) δ 12.11 (br s, 1H), 7.47 (s, 1H), 7.42-7.38 (m, 1H), 7.14-7.08 (m, 2H), 6.67 (s, 1H), 3.87-3.84 (m, 8H).
Example 3
Preparation of Compound 5a
[0043] Imidazole (0.42 g) and 1,1′-carbonyldiimidazole (5.49 g) were slurried in 30 mL of THF at ambient temperature. Compound 4 (10 g) was added in one portion and the mixture was stirred at ambient temperature until the reaction was complete by HPLC. The resulting slurry was filtered and the solids washed with MTBE. The solids were dried to yield Compound 5a: 1 H NMR (DMSO-d 6 , 400 MHz) δ 7.99 (s, 1H), 7.52 (s, 1H), 7.41-7.38 (m, 1H), 7.30 (s, 1H), 7.12-7.08 (m, 2H), 7.04 (s, 1H), 6.81 (s, 1H), 3.91 (s, 2H), 3.90 (s, 3H), 3.79 (s, 3H).
Example 4
Preparation of Compound 6a
[0044] Imidazole (0.42 g) and 1,1′-carbonyldiimidazole (5.49 g) were slurried in 30 mL of THF at ambient temperature. Compound 5a (10 g) was added in one portion and the mixture was stirred at ambient temperature for 4 hours to form a slurry of compound 5a. In a separate flask, 8.91 g of potassium monoethyl malonate was slurried in 40 mL of THF. Magnesium chloride (4.40 g) was added and the resulting slurry was warmed to 55° C. for 90 minutes. The slurry of Compound 5a was transferred to the magnesium chloride/potassium monoethyl malonate mixture and stirred at 55° C. overnight. The mixture was then cooled to room temperature and quenched by the dropwise addition of 80 mL of 28 wt % aqueous H 3 PO 4 . The phases were separated and the organic phase was washed successively with aqueous NaHSO 4 , KHCO 3 and NaCl solutions. The organic phase was concentrated to an oil and then coevaporated with ethanol. The resulting solid was dissolved in 30 mL ethanol and 6 mL water. Compound 6a was crystallized by cooling. The solid was isolated by filtration and the product was washed with aqueous ethanol. After drying Compound 6a was obtained: 1 H NMR (DMSO-d 6 , 400 MHz) δ 7.51 (s, 1H), 7.42-7.38 (m, 1H), 7.12-7.10 (m, 2H), 6.70 (s, 1H), 4.06 (q, J=7.0 Hz, 2H), 3.89 (s, 8H), 3.81 (s, 2H), 1.15 (t, J=7.0 Hz, 3H).
[0045] Alternatively, Compound 6a can be prepared as follows.
[0046] Carbonyldiimidazole (10.99 g) was slurried in 60 mL of THF at ambient temperature. Compound 4 (20 g) was added in one portion and the mixture was stirred at ambient temperature for 30 min to form a slurry of compound 5. In a separate flask 15.72 g of potassium monoethyl malonate was slurried in 100 mL of THF. Magnesium chloride (6.45 g) was added and the resulting slurry was warmed to 55° C. for 5 hours. The slurry of Compound 5 was transferred to the magnesium chloride/potassium monoethyl malonate mixture and stirred at 55° C. overnight. The mixture was then cooled to room temperature and quenched onto 120 mL of 28 wt % aqueous H 3 PO 4 . The phases were separated and the organic phase was washed successively with aqueous KHCO 3 and NaCl solutions. The organic phase was concentrated to an oil and then coevaporated with ethanol. The resulting solid was dissolved in 100 mL ethanol and 12 mL water. Compound 6a was crystallized by cooling. The solid was isolated by filtration and the product was washed with aqueous ethanol. After drying 21.74 g Compound 6a (89% yield) was obtained: 1 H NMR (DMSO-d 6 , 400 MHz) δ 7.51 (s, 1H), 7.42-7.38 (m, 1H), 7.12-7.10 (m, 2H), 6.70 (s, 1H), 4.06 (q, J=7.0 Hz, 2H), 3.89 (s, 8H), 3.81 (s, 2H), 1.15 (t, J=7.0 Hz, 3H).
Example 5
Preparation of Compound 9a
[0047] Compound 6a (20 g) was stirred with 6.6 g dimethylformamide dimethyl acetal, 66 g toluene and 0.08 g glacial acetic acid. The mixture was warmed to 90° C. for 4 hours. The mixture was then cooled to ambient temperature and 5.8 g (S)-2-amino-3-methyl-1-butanol was added. The mixture was stirred at ambient temperature for 1 hour before being concentrated to a thick oil. Dimethylformamide (36 g), potassium chloride (1.8 g) and bis(trimethylsilyl)acetamide (29.6 g) were added and the mixture was warmed to 90° C. for 1 h. The mixture was cooled to room temperature and diluted with 200 g dichloromethane. Dilute hydrochloride acid (44 g, about 1N) was added and the mixture stirred at ambient temperature for 20 min. The phases were separated and the organic phase was washed successively with water, aqueous sodium bicarbonate and water. The solvent was exchanged to acetonitrile and the volume was adjusted to 160 mL. The mixture was heated to clarity, cooled slightly, seeded and cooled to crystallize Compound 9a. The product was isolated by filtration and washed with additional cold acetonitrile. Vacuum drying afforded Compound 9a: 1 H NMR (DMSO-d 6 , 400 MHz) δ 8.61 (s, 1H), 7.86 (s, 1H), 7.45 (t, J=7.4 Hz, 1H), 7.26 (s, 1H), 7.23-7.14 (m, 2H), 5.10 (br s, 1H), 4.62 (br s, 1H), 4.18 (q, J=7.0 Hz, 2H), 4.03 (s, 2H), 3.96 (s, 3H), 3.92-3.84 (m, 1H), 3.78-3.75 (m, 1H), 2.28 (br s, 1H), 1.24 (t, J=7.0 Hz, 3H), 1.12 (d, J=6.4 Hz, 3H), 0.72 (d, J=6.4 Hz, 3H).
[0048] Alternatively, Compound 9a can be prepared as follows.
[0049] Compound 6a (50 g) was stirred with 17.5 g dimethylformamide dimethyl acetal, 90 g DMF and 0.2 g glacial acetic acid. The mixture was warmed to 65° C. for 3 hours. The mixture was then cooled to ambient temperature and 14.5 g (S)-2-amino-3-methyl-1-butanol and 25 g toluene were added. The mixture was stirred at ambient temperature overnight before being concentrated by distillation. Potassium chloride (4.5 g) and bis(trimethylsilyl)acetamide (80.2 g) were added and the mixture was warmed to 90° C. for 2 h. The mixture was cooled to room temperature and diluted with 250 g dichloromethane. Dilute hydrochloride acid (110 g of ˜1N) was added and the mixture stirred at ambient temperature for 30 min. The phases were separated and the organic phase was washed successively with water, aqueous sodium bicarbonate and water. The solvent was exchanged to acetonitrile by distillation. The mixture was heated to clarity, cooled slightly, seeded and cooled to crystallize Compound 9a. The product was isolated by filtration and washed with additional cold acetonitrile. Vacuum drying afforded 48.7 g (81% yield) of Compound 9a: 1 H NMR (DMSO-d 6 , 400 MHz) δ 8.61 (s, 1H), 7.86 (s, 1H), 7.45 (t, J=7.4 Hz, 1H), 7.26 (s, 1H), 7.23-7.14 (m, 2H), 5.10 (br s, 1H), 4.62 (br s, 1H), 4.18 (q, J=7.0 Hz, 2H), 4.03 (s, 2H), 3.96 (s, 3H), 3.92-3.84 (m, 1H), 3.78-3.75 (m, 1H), 2.28 (br s, 1H), 1.24 (t, J=7.0 Hz, 3H), 1.12 (d, J=6.4 Hz, 3H), 0.72 (d, J=6.4 Hz, 3H).
Example 6
Preparation of Compound 10
[0050] Compound 9a (6.02 g) was slurried in 36 mL isopropanol and 24 mL of water. Aqueous potassium hydroxide (2.04 g of 45 wt % solution) was added and the mixture warmed to 40° C. After 3 hours 1.13 g glacial acetic acid was added the mixture seeded with 10 mg of Compound 10. The mixture was cooled in an ice bath for 2 hours and the solid was isolated by filtration. The cake was washed with aqueous isopropanol and dried to give Compound 10: 1 H NMR (DMSO-d 6 , 400 MHz) δ 15.42 (s, 1H), 8.87 (s, 1H), 8.02 (s, 1H), 7.48-7.45 (m, 2H), 7.23 (t, J=6.8 Hz, 1H), 7.17 (t, J=7.8 Hz, 1H), 5.18 (br s, 1H), 4.86 (br s, 1H), 4.10 (s, 2H), 4.02 (s, 3H), 3.97-3.96 (m, 1H), 3.79-3.76 (m, 1H), 2.36 (br s, 1H), 1.14 (d, J=6.3 Hz, 3H), 0.71 (d, J=6.3 Hz, 3H).
[0051] Alternatively, Compound 10 can be prepared from Compound 4 as described in the following illustrative Examples 7-9.
Example 7
Preparation of a Compound of Formula 6a
[0052]
[0053] Carbonyldiimidazole and imidazole are combined with anhydrous tetrahydrofuran. Compound 4 is added to this mixture to form Compound 5 and the reaction is monitored by HPLC. In a separate reactor potassium monoethylmalonate is combined with tetrahydrofuran before anhydrous magnesium chloride is added while maintaining the temperature NMT 30° C. The resulting slurry is warmed to 50° C. and held for at least two hours before the Compound 5 mixture is added. The reaction is monitored by HPLC. Once the formation of Compound 5 is complete, the mixture is cooled to 18 to 25° C. and added to aqueous phosphoric acid to quench. The organic phase is washed with aqueous sodium bisulfate, brine, potassium bicarbonate and brine solutions before being polish filtered. The solvent is exchanged for anhydrous ethanol. Water is added and the mixture is warmed to dissolve solids, cooled to about 40° C., seeded with Compound 6a and cooled to 0 to 5° C. The product is filtered, washed with cold aqueous ethanol and dried at NMT 40° C. to yield Compound 6a.
[0000]
Material
M.W.
Wt. Ratio
Mole Ratio
Compound 4
324.73
1.000
1.00
THF
72.11
7.11
Imidazole
68.08
0.042
0.20
CDI
162.15
0.55
1.10
KEM
170.2
0.89
1.70
MgCl 2
95.21
0.44
1.50
H 3 PO 4 (85 wt %)
98.00
2.3
NaHSO 4
120.06
0.24
KHCO 3
100.12
0.50
NaCl
58.44
0.48
SDA 2B-2 EtOH (0.5% heptane)
46.07
~10 kg
Procedure:
[0000]
1. Charge 0.55 kg CDI and 0.042 kg imidazole to reactor 1.
2. Charge 2.67 kg THF to reactor 1 and agitate to form a slurry.
3. Charge 1.00 kg Compound 4 to reactor 1 in portions to moderate the CO 2 offgas. This addition is endothermic
4. Charge 0.89 kg KEM to reactor 2.
5. Charge 4.45 kg THF to reactor 2 and agitate to form a slurry.
6. Charge 0.44 kg MgCl 2 to reactor 2 (can be added in portions to moderate exotherm).
7. Warm the contents of reactor 2 to 50° C. and agitate at that temperature for at least two hours.
8. Transfer the contents of reactor 1 to reactor 2. Mixture will become thick temporarily if transferred very rapidly.
9. Agitate the contents of reactor 2 for at least 12 hours at 50° C.
10. Cool the slurry to ambient temperature.
11. Quench the reaction by transferring the reaction mixture onto 7.0 kg of 28 wt % aqueous H 3 PO 4 (2.3 kg 85 wt % H 3 PO 4 dissolved in 4.7 kg H 2 O). This addition is exothermic. Final pH of aqueous layer should be 1-2.
12. Wash the organic (top) phase with 1.2 kg of 20 wt % aqueous NaHSO 4 (0.24 kg of NaHSO 4 dissolved in 0.96 kg H 2 O). Final pH of aqueous layer should be 1-2.
13. Wash the organic (top) phase with 1.2 kg of 20 wt % aqueous NaCl (0.24 kg of NaCl dissolved in 0.96 kg H 2 O)
14. Wash the organic (top) phase with 5.0 kg of 10 wt % aqueous KHCO 3 (0.50 kg of KHCO 3 dissolved in 4.5 kg H 2 O). Final pH of aqueous layer should be 8-10.
15. Wash the organic (top) phase with 1.2 kg of 20 wt % aqueous NaCl (0.24 kg of NaCl dissolved in 0.96 kg H 2 O). Final pH of aqueous layer should be 7-9.
16. Concentrate the organic phase and exchange the solvent to EtOH.
17. Adjust the concentration to ˜3.5 L/kg input.
18. Charge 0.6 volumes of water.
19. Warm 70-80° C. to form a clear solution.
20. Cool to 40° C. and seed with 0.1 wt % Compound 6.
21. Cool slowly to 5° C.
22. Hold for at least 2 hours.
23. Filter and wash the cake with two 1.35 kg volume portions of 50:50 EtOH:H 2 O (1.2 kg EtOH combined with 1.5 kg H 2 O).
24. Dry the cake at less than 50° C.
Example 8
Preparation of a Compound of Formula 9a
[0078]
[0079] Compound 6a is combined with toluene, N,N-dimethylformamide dimethyl acetal and glacial acetic acid before being warmed to 100° C. The reaction is monitored by HPLC. Once the formation of Compound 7a is complete the mixture is cooled to 18 to 25° C. before (5)-(+)-valinol is added. The reaction is monitored by HPLC. Once the formation of Compound 8a is complete the mixture is concentrated. The residue is combined with dimethylformamide, potassium chloride and N,O-bisnimethylsilyl acetamide and warmed to 100° C. The reaction is monitored by HPLC. Once complete the mixture is cooled and dichloromethane is added. Aqueous hydrochloric acid is added to desilylate Compound 9a. This reaction is monitored by TLC. Once complete the organic phase is washed with water, aqueous sodium bicarbonate and water. The solvent is exchanged for acetonitrile and the mixture warmed. The mixture is seeded and cooled to crystallize Compound 9a. The product is filtered, washed with cold acetonitrile and dried at NMT 40° C. to yield Compound 9a.
[0000]
Material
M.W.
Wt. Ratio
Mole Ratio
Compound 6a
394.82
1.00
1.00
Toluene
92.14
4.3
Glacial acetic acid
60.05
0.001
0.007
N,N-dimethylformamide dimethyl
119.16
0.33
1.1
acetal
(S)-(+)-Valinol
103.16
0.29
1.1
DMF
73.10
1.8
KCl
74.55
0.09
0.5
N,O-bis(trimethylsilyl)acetamide
203.43
1.13
2.2
1 N HCl
36.5
2.0
DCM
84.93
10
Water
18.02
8
5% Aq. NaHCO 3
84.01
4
CAN
41.05
QS
Compound 9a seeds
475.94
0.005
1. Charge Reactor 1 with 1.00 kg Compound 6a.
2. Charge 0.33 kg N,N-dimethylformamide dimethyl acetal (1.1 eq), 0.001 kg glacial acetic acid and 3.3 kg toluene to Reactor 1.
3. Warm the mixture to ˜100° C. (note that some MeOH may distill during this operation).
4. After 1 h the reaction should be complete by HPLC (˜2% Compound 6a apparently remaining) 1 .
5. Cool the mixture in Reactor 1 to 18-25° C.
6. Charge 0.29 kg (S)-(+)-Valinol (1.1 eq) dissolved in 1.0 kg toluene to Reactor 1 and continue agitation at ambient temperature.
7. After 1 h the reaction should be complete by HPLC (<1% Compound 6a).
8. Concentrate the contents of Reactor 1 to ˜2 L/kg.
9. Charge 1.8 kg DMF, 0.09 kg potassium chloride (0.5 eq,) and 1.13 kg N,O-bistrimethylsilyl acetamide (2.2 eq.) to Reactor 1.
10. Warm the mixture in Reactor 1 to ˜100° C.
11. Reaction should be complete in ˜1 h (˜5% Compound 8a remaining).
12. Cool the contents of Reactor 1 to 18-25° C.
13. Charge 10 kg DCM to Reactor 1.
14. Charge 2.0 kg 1 N aqueous HCl to Reactor 1 over ˜15 min, maintaining the temperature of the mixture<35° C.
15. Agitate the mixture for at least 10 min to desilylate Compound 8a. Monitor the progress of desilylation by TLC. 2
16. Separate the phases.
17. Wash the organic phase with 4.0 kg water.
18. Wash the organic phase with 4.0 kg 5% aqueous sodium bicarbonate.
19. Wash the organic phase with 4.0 kg water.
20. Concentrate the organic phase by distillation to ˜1.5 L/kg Compound 6a.
21. Solvent exchange to ACN by distillation until a slurry is formed. Adjust the final volume to ˜8 L/kg Compound 6a.
22. Heat the mixture to reflux to redissolve the solid.
23. Cool the solution to 75° C. and charge Compound 9a seeds.
24. Cool the mixture to 0° C. over at least 2 h and hold at that temperature for at least 1 h.
25. Isolate Compound 9a by filtration and wash the wet cake with 1.6 kg cold ACN.
26. Dry the wet cake at <40° C. under vacuum.
Notes:
[0000]
1. The HPLC AN of remaining Compound 6a is exaggerated by a baseline artifact. The HPLC in step shows only 2% of Compound 6a relative to Compound 8a. Experiments demonstrated that adding more reagent and extending reaction time typically will not further reduce the observed level of Compound 6a.
2. TLC method:
Eluting solvent: 100% ethyl acetate, Silylated Compound 9a Rf: 0.85, Compound 9a Rf: 0.50.
Example 9
Preparation of a Compound of Formula 10
[0110]
[0111] Compound 9a is combined with aqueous isopropyl alcohol and warmed to 30 to 40° C. Aqueous potassium hydroxide is added and the reaction is monitored by HPLC. Once complete, glacial acetic acid is added and the mixture warmed to 60 to 70° C. The solution is hot filtered and cooled to 55 to 65° C. The solution is seeded (see International Patent Application Publication Number WO 2005/113508) and cooled to 0° C. The product is isolated by filtration, washed with cold aqueous isopropyl alcohol and dried at NMT 50° C. to yield Compound 10.
[0000]
Material
M.W.
Wt. Ratio
Mole Ratio
Compound 9a
475.94
1.00
1.00
Isopropyl alcohol
60.10
4.7
Water
18.02
4.0
45% KOH
56.11
0.34
1.3
Glacial Acetic Acid
60.05
0.19
1.50
Compound 10 seeds
447.88
0.01
1. Charge 1.00 kg Compound 9a to Reactor 1.
2. Charge 4.7 kg isopropyl alcohol and 4.0 kg water to Reactor 1.
3. Charge 0.34 kg 45% aqueous KOH to Reactor 1.
4. Warm the mixture in Reactor 1 to 30-40° C.
5. When hydrolysis is complete add 0.19 kg of glacial acetic acid.
6. Warm the mixture to 60-70° C. and polish filter the solution to Reactor 2.
7. Cool the mixture in Reactor 2 to 55-65° C.
8. Seed with Compound 10 (see International Patent Application Publication Number WO 2005/113508) as a slurry in 0.28 volumes of 6:4 isopropyl alcohol:water.
9. Cool the mixture to 18-25° C. over at least 2 h and agitate to form a slurry.
10. Cool the mixture to 0° C. and agitate for at least 2 h.
11. Isolate Compound 10 by filtration and wash the cake with 3×1 S cold isopropyl alcohol:water (6:4) solution.
12. Dry the isolated solids at <50° C. under vacuum.
Example 10
Preparation of Compound 15
[0124]
[0125] Bisdimethylaminoethyl ether (2.84 g) was dissolved in 42 mL THF and cooled in an ice bath. Isopropylmagnesium chloride (8.9 mL of a 2 M solution in THF) followed by Compound 14 (5 g dissolved in 5 mL THF) were added slowly sequentially. The mixture was allowed to warm to ambient temperature and stirred overnight. Next, 2.1 mL of 3-chloro-2-fluorobenzaldehyde was added. After stirring for ˜1 h, the mixture was quenched to pH˜7 with 2N HCl. The product was extracted into ethyl acetate and the organic phase was dried over sodium sulfate. The solvent was exchange to heptane to precipitate the product and a mixture of heptanes:MTBE (4:1) was added to form a slurry. After filtration the solid was slurried in toluene, filtered and vacuum dried to yield compound 15: 1 H NMR (CD 3 CN, 400 MHz) δ 7.47 (s, 1H), 7.41-7.35 (m, 2H), 7.15 (t, J=7.4 Hz, 1H), 6.66 (s, 1H), 6.21 (br s, 1H), 3.90 (s, 3H), 3.87 (br s, 1H), 3.81 (s, 3H).
Example 11
Preparation of Compound 15a
[0126]
[0127] Compound 14 (5 g), isopropylmagnesium chloride (8.9 mL of 2M solution in THF) and THF (56 mL) were combined at ambient temperature and then warmed to 50° C. for ˜5 hours. After cooling to ambient temperature and stirring overnight, 2.1 mL of 3-chloro-2-fluorobenzaldehyde was added dropwise to form a slurry. After stirring overnight the solid was isolated by filtration and washing with MTBE to yield compound 15a.
Example 12
Preparation of Compound 16
[0128]
[0129] Triethylsilane (1.2 mL) was added to trifluoroacetic acid (2.3 mL) that had been pre-cooled in an ice bath. Compound 15 (1.466 g) was added to the mixture keeping the temperature below 5° C. After stirring for ˜2 h ice was added to quench the reaction. The product was extracted with DCM and the organic phase was washed with aq. NaHCO 3 . The organic phase was dried over Na 2 SO 4 and concentrated to dryness. The product was purified by silica gel column chromatography to provide 1.341 g of Compound 16: 1 H NMR (CDCl 3 , 400 MHz) δ 7.20 (t, J=7.0 Hz, 1H), 6.99-6.91 (m, 3H), 6.46 (s, 1H), 3.91 (s, 3H), 3.81 (s, 5H).
[0130] The compound of formula 16 can be carboxylated to provide a compound of Formula 4 following a method analogous to that described in Example 1.
Example 13
Alternative Preparation of a Compound of Formula 3
[0131] Compound 14 is combined with anhydrous tetrahydrofuran:dioxane (5:0.9), and the mixture is agitated under a nitrogen atmosphere until a homogeneous solution is achieved. The solution is cooled to −3° C. and 1.3 eq. of i-PrMgCl.LiCl in tetrahydrofuran is added. The reaction mixture is agitated at 0° C. until the formation of the mono-Grignard is complete as determined by HPLC analysis. Next, a solution of 1.1 eq. of 3-chloro-2-fluorobenzaldehyde in tetrahydrofuran is added. This mixture is allowed to stir at 0° C. until the formation of Compound 15a is complete by HPLC. Next, additional i-PrMgCl.LiCl solution in tetrahydrofuran (2.5 eq.) is added and the reaction mixture is warmed to about 20° C. After conversion to the second Grignard intermediate is complete, the reaction mixture is cooled to 3° C. Anhydrous CO 2 (g) is charged to the reaction mixture at about 5° C. The reaction mixture is adjusted to about 20° C. After the carboxylation reaction is complete by HPLC, the reaction mixture is cooled to about 10° C. and water is charged to quench the reaction followed by the addition of concentrated hydrochloric acid to adjust the pH to no more than 3. The reaction mixture is then warmed to about 20° C. The phases are separated. The organic phase is solvent exchanged to a mixture of isopropyl alcohol and water and the resulting slurry is cooled to about 0° C. The product is isolated by filtration, washed with a mixture of isopropyl alcohol and water and dried at about 40° C. to yield Compound 3.
Example 14
Alternative Preparation of Compound of Formula 4
[0132] Trifluoroacetic acid (10 eq.) is charged to a reactor and cooled to 0° C. Triethylsilane (1.5 eq.) is added maintaining the temperature<15° C. and the mixture agitated thoroughly. Compound 3 is added to the well-stirred mixture in portions maintaining the temperature<15° C. When the reaction is determined to be complete by HPLC, Compound 4 is precipitated by adding a solution of 5 eq. sodium acetate in methanol (13 volumes) maintaining the temperature not more than 45° C. Warm the slurry to reflux and agitate for 2 to 3 h. The slurry is cooled to about 0° C. and then agitated at that temperature for 2 to 3 h. The product is isolated by filtration, washed with methanol and dried at about 40° C. to yield Compound 4.
Example 15
Alternative Preparation of a Compound of Formula 9a
[0133] Compound 6a is combined with dimethylformamide (1.9 vol.),
[0134] N,N-dimethylformamide dimethyl acetal (1.1 eq.) and glacial acetic acid (0.026 eq.) before being warmed to about 65° C. The reaction is monitored by HPLC. Once the reaction is complete the mixture is cooled to about 22° C. before (S)-2-amino-3-methyl-1-butanol (1.1 eq.) and toluene (1.2 volumes) are added. The reaction is monitored by HPLC. Once the reaction is complete the mixture is concentrated. The residue is combined with potassium chloride (0.5 eq) and N,O-bis(trimethylsilyl)acetamide (2.5 eq.) and warmed to about 100° C. The reaction is monitored by HPLC. Once the reaction is complete the mixture is cooled and dichloromethane (6 vol.) is added. Aqueous hydrochloric acid is added to desilylate the product. This reaction is monitored by TLC. Once the reaction is complete the organic phase is washed with water, aqueous sodium bicarbonate and water. The solvent is exchanged for acetonitrile and the mixture is warmed to form a solution. The mixture is seeded and cooled to crystallize Compound 9a. The product is filtered, washed with cold acetonitrile and dried at NMT 40° C. to yield Compound 9a.
[0135] All publications, patents, and patent documents are incorporated by reference herein, as though individually incorporated by reference. The invention has been described with reference to various specific and preferred embodiments and techniques. However, it should be understood that many variations and modifications may be made while remaining within the spirit and scope of the invention. | The invention provides synthetic processes and synthetic intermediates that can be used to prepare 4-oxoquinolone compounds having useful integrase inhibiting properties. | 2 |
BACKGROUND
[0001] 1. Field of the Invention
[0002] The present invention relates to a method for forming a carbon-metal composite material for a heat sink, and a heat sink which has at least one shaped body.
[0003] 2. Background
[0004] WO 2010/057236 describes a heat sink and a method of producing the heat sink. The heat sink has a base body comprising an insertion body that consists of a carbon-metal composite material and that is spaced away from a positioning surface for positioning a component to be cooled, e.g. a laser diode. Silver-diamond, copper-diamond and aluminium-diamond, in particular, are specified as carbon-metal composite materials.
[0005] The insertion body can be produced by filling a receptacle with a carbon phase and a metallic phase, the metallic phase in the (molten) liquid state entering the receptacle in order to infiltrate the carbon phase. Both unpressurised processes and processes with pressure support, e.g. a GPI process (Gas Pressure Infiltration Process), can be used for the purposes of infiltration. Irrespective hereof, hot pressing of the insertion body is alternatively described as a further production method.
[0006] Owing to the low quality of the upper surface of the insertion body produced in the way described above and the fact that post-processing of the insertion body, for example by polishing, is possible only at considerable expense, it is suggested that the insertion body, after it has been received in the base body, be applied at a distance from the positioning surface for application of the component and covered, for example, with a solder layer.
[0007] U.S. Pat. No. 5,273,790 discloses a method for consolidating synthetic diamonds or diamond composite materials that can be used, inter alia, for cooling electronic components. For this purpose, particles of diamond or other materials are infiltrated with diamond material having a high thermal conductivity using a CVD method. A volume of the consolidated diamond material or diamond composite material can be structured in layers by infiltrating a respective layer or preform of diamond or other materials with diamond material using a CVD method.
[0008] US 2007/0071907 describes an article or body which has an iron-containing substrate and a wear-resistant layer that consists of a composite material. The composite material has diamond particles in a metal matrix. In order to form the composite material, a particle mixture of diamond particles and metal particles is applied to the iron-containing substrate and the mixture is heated in a non-reactive atmosphere using a laser beam in order to fuse the metal particles so that they bond with the substrate and with the diamond particles to the wear-resistant layer. In order to prevent the diamond particles being damaged by the laser radiation, a material having a melting point of between 400 and 900° C., in particular silver or copper, is recommended as the metallic matrix material.
SUMMARY
[0009] The object of the present invention is to provide a method for forming a carbon-metal composite material for a heat sink, and a heat sink, in which a composite material having improved properties can be produced and the effort of forming the composite material can be reduced.
[0010] This object is achieved according to the invention by a method for forming a carbon-metal composite material for a heat sink, in which at least one layer comprising carbon particles and at least one layer comprising metal particles are applied on top of one another, wherein the layers are fused by irradiating the layers with laser radiation to form (a layer of) the carbon-metal composite material. The metal particles and the carbon particles are typically applied here in the form of a powder.
[0011] Through the laser radiation, a fusion zone is formed in which the layer(s) with the metal particles is/are fused so that the metal particles in molten liquid form can penetrate the layer(s) of carbon particles and infiltrate them and the carbon particles are enclosed in a metallic matrix. The layers are typically fused in a non-reactive environment, e.g. in an inert gas environment or under vacuum.
[0012] In one variant, in order to form a shaped body from the carbon-metal composite material, the applying and the fusing of layers is repeated a number of times. By the method according to the invention, a shaped body can be structured in layers, wherein the geometry, in particular the length and width of the layers of the carbon-metal composite material, can be varied in order to give the shaped body a desired geometry or to adjust the geometry of the shaped body to the desired end contour. The shaped body of the composite material formed in this way has a layer structure, it being possible for the properties of the composite material, for example the ratio of carbon to metal, to be adjusted flexibly in a respective layer by applying a number of layers on top of one another.
[0013] In a further variant, a final layer of the shaped body is post-processed. The final layer, i.e. the last layer of the shaped body structured in layers, can serve for application of a component, e.g. a laser diode, a laser disc or the like. In order to be able to position this component with the desired accuracy and ensure high thermal conductivity, it is advantageous, on the upper surface of the final layer, to carry out post-processing or finishing with a high level of precision in order to achieve a low surface roughness.
[0014] The production of the shaped body in layers according to the invention makes it possible to obtain a defined final layer that can easily be post-processed or polished. In particular, for the last layer(s), only metal particles can be provided in order to facilitate post-processing. In this variant, in order to form a final layer for the shaped body, a layer comprising metal particles is applied and fused by irradiation with laser radiation so that a metal layer is produced that bonds with a layer of the carbon-metal composite material lying underneath it. The material of the metal particles usually corresponds to the metallic material that is also used to form the carbon-metal composite material so that the final layer and the layers of carbon-metal composite material can be produced in one and the same production process. The final layer has, in this case, (virtually) no carbon particles and can therefore easily be post-processed. The final layer can also be formed of a number of individual layers.
[0015] It is also (alternatively) possible for a layer of the carbon-metal composite material, for the production of which a comparatively thick layer comprising metal particles is used, to serve as a final layer so that, after fusing with the layer of carbon particles, there are as far as possible no or only very few carbon particles in the upper area of the final layer.
[0016] The layers of metal and carbon particles can be applied before the application of laser radiation. However, in particular with respect to the application of the metal particles, it is also possible for particles to be supplied during the application of laser radiation, for example coaxially to the laser beam.
[0017] In one variant, at least two of the layers have carbon particles with different granulation (mean particle size). A small granulation may possibly be advantageous in layers that are located close to the final layer. A larger granulation may, for example, be advantageous in layers located further away from the final layer.
[0018] In one variant, at least two layers of the carbon-metal composite material are produced having a different volume ratio of carbon particles to a metal matrix formed from metal particles. As a result of the separate application of the carbon particles and metal particles, the material composition of the shaped body may vary from layer to layer. The desired ratio can, for example, be obtained by setting the ratio of the thickness of the layer of metal particles to the thickness of the layer of carbon particles appropriately. It is self-evident that the thickness of the layer of carbon-metal composite material respectively formed during fusing can also be varied within certain limits by choosing the thickness of the particle layers.
[0019] In addition to the variation of the layer composition through the particle sizes and particle volumes used, the properties of the shaped body can also be influenced via the defined structure of the shaped body comprising different layers. For example, the layers of the shaped body first applied to the substrate may be layers of metal particles and a metal-carbon composite may only be introduced in the following layers. In other words, the composition of the individual layers and the structure of the shaped body comprising these layers are freely selectable.
[0020] In a refinement, the metal particles are selected from the group comprising: copper, silver, gold, aluminium, tin and titanium. In particular, silver and copper in a composition with diamond have proven to be advantageous as a composite material owing to their very high thermal conductivity. If such a composite material is used as a heat sink for a component comprising gallium arsenide (e.g. a high-performance laser diode), the thermal expansion or the thermal expansion coefficient of the heat sink is adjusted to the thermal expansion of the component. The difference between the thermal expansion coefficient of the component and that of the composite material in such an adjustment is typically less than 2×10 −6 1/K.
[0021] In a further variant, the carbon particles are selected from the group comprising: diamond, graphite and carbide. In particular, diamond has proven to be especially advantageous for the production of a composite material owing to its high thermal conductivity. Within the meaning of this application, carbon particles are also understood to refer to compounds containing carbon, in particular carbide.
[0022] One variant comprises applying at least one layer of metal particles to a substrate and fusing the layer to the substrate through laser radiation. In this variation, one or more metallic layers are applied to a substrate and fused to it before layers comprising metal particles and comprising carbon particles are alternately fused with one another. In this way, the adhesion of the composite material to the substrate can be increased and a smooth surface can be achieved for the application of the composite material.
[0023] In a further variant, at least one layer comprising carbon particles is applied with a density varying in a thickness direction. The layers are typically applied such that the particles have, as far as possible, a constant thickness in the thickness direction. However, in order to produce a gradient layer, it may be advantageous if the density or the number of carbon particles in the thickness direction varies, the latter typically increasing or decreasing with the increasing thickness of the layer.
[0024] A further aspect of the invention is realised in a heat sink for a component, comprising a shaped body of a carbon-metal composite material, which comprises a plurality of layers, each layer containing carbon particles in a metal matrix surrounding the carbon particles. The carbon-metal composite material can be produced here, in particular, in the way described above. The heat sink may, if applicable, consist only of the shaped body (applied to a substrate) which, if applicable, is post-processed to produce the desired end contour(s). Alternatively, it is also possible to form the shaped body within a receptacle of a base body of a heat sink or to bond the shaped body to the base body of the heat sink, for example through soldering.
[0025] In one embodiment, the heat sink has a component to be cooled, for example a (high-performance) laser diode or a laser disc, which is arranged on a positioning surface formed on the shaped body. In particular, carbon-metal composite materials of copper and diamond or of silver and diamond have shown themselves to be particularly advantageous for cooling laser diodes or laser discs. A laser disc is a plate-shaped solid state medium which contains a laser-active material or consists thereof. The laser-active medium typically has a host crystal (YAG, YVO4, etc.) that has been provided with an active material (Yb3, Nd3+, Ho, Tm3, etc.). The laser-active medium may, for example, be Yb:YAG, Nd:YAG or Nd:YVO4. The plate-shaped laser disc usually has a circular geometry, but this is not absolutely necessary, i.e. the laser disc may also have, for example, a square or rectangular geometry.
[0026] The component to be cooled may be applied to the positioning surface or bonded to the shaped body in various ways, for example using a joining agent, e.g. though a solder connection (using at least one solder layer) or through an adhesive connection (by means of at least one adhesive layer). It is self-evident that a good thermal coupling between the component and the shaped body should be ensured irrespective of the connection method chosen. An adhesive layer used for this purpose may be formed, for example, as in EP 1 178 579 A2, which is included in this application by reference.
[0027] In a further embodiment, the component to be cooled is arranged directly on the positioning surface, i.e. without the use of additional intermediate layers, e.g. in the form of solder layers or adhesive layers. In this case, the shaped body typically has a positioning surface with a low upper surface roughness. This low upper surface roughness can, for example, be achieved by post-processing of the positioning surface. The positioning surface may be formed here on a final layer of the shaped body, which final layer consists of the carbon-metal composite material, so that the component to be cooled by means of the heat sink can be applied directly onto the positioning surface of the carbon-metal composite material. Alternatively, a layer formed from metal particles can be applied to a layer of the carbon-metal composite material as a final layer, the material of the metal particles of the final layer typically corresponding to the material of the metal particles of the composite material. A positioning surface having a low surface roughness has also shown itself to be advantageous when using an intermediate layer, e.g. an adhesive layer or a solder layer.
[0028] In a further embodiment, the heat sink comprises a base body for application of the shaped body. The shaped body may be bonded to the base body, for example through soldering, or a receptacle may be provided in order to receive the shaped body. In the latter case, the layers can be applied directly in the receptacle and fused with one another there under the effect of laser radiation. The final layer or the cover layer of the shaped body may essentially end here flush with the upper edge of the base body and serve as a positioning surface for the component to be cooled after corresponding post-processing.
[0029] Further advantages of the invention are disclosed in the description and the drawings. The features specified above and those yet to be described below can each be used per se or in a number of desired combinations. The embodiments shown and described are not to be understood as an exhaustive list, but are instead examples to describe the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] FIGS. 1 a - d show schematic representations of a method for forming a layer of diamond-metal composite material,
[0031] FIGS. 2 a,b show cross-sectional representations of a detail of a heat sink having a shaped body consisting of a diamond-metal composite material without and with a component to be cooled, and
[0032] FIG. 3 shows a schematic, perspective representation.
DETAILED DESCRIPTION
[0033] FIGS. 1 a - d show a chamber 1 for forming a layer of a carbon-metal composite material, in the present example in the form of a diamond-copper composite material. In order to create a non-reactive environment in the chamber 1 , the chamber 1 has a connection 2 for feeding in an inert gas, e.g. nitrogen. However, the chamber 1 may also be connected to a vacuum pump in order to create a non-reactive environment inside the chamber 1 .
[0034] A substrate 3 , for example of copper, is arranged in the chamber 1 . A device 4 for distributing particles is arranged above the substrate 3 and is connected to two particle reservoirs (not shown) via a central feed line. The device 4 has a number of evenly spaced openings (not represented graphically) from which particles can emerge as indicated by arrows.
[0035] In the example shown in FIG. 1 a , (pulverulent) diamond particles 5 emerge from the device 4 , sink onto the substrate 3 under the effect of gravity and form a layer 5 a of diamond particles 5 there as shown in FIG. 1 b . In order to obtain the most homogeneous distribution of diamond particles 5 possible in the layer 5 a, the device 4 may, for example, be displaced parallel to the substrate 3 (i.e. in the XY plane) during the application, for example in the manner of a vibrating sieve.
[0036] In a subsequent step shown in FIG. 1 b , copper particles 6 are applied to the layer 5 a comprising diamond particles 5 . For this purpose, the connection between the central feed of the device 4 and the reservoir of diamond particles is disabled and the feed is connected to a reservoir of copper particles 6 so that a layer 6 a of copper particles 6 is formed on the diamond layer 5 a, cf. FIG. 1 c.
[0037] In a subsequent step, a laser beam 7 , which is generated, for example, by a laser (not shown), is irradiated on the layers 5 a, 6 a arranged one on top of the other, a fusion zone being formed in the area where the laser beam 7 hits. The laser beam 7 is moved here in a scanning manner over the surface of the layers 5 a, 6 a, as a result of which the latter fuse with one another to form a diamond-copper composite material 8 which also bonds to the substrate 3 , cf. FIG. 1 d . The diamond-copper composite material 8 has a copper matrix 9 here in which the diamond particles 5 are embedded. In order to enable the laser beam 7 to scan, a processing head (not shown) is moved under the openings in the XY plane. The wavelength of the laser beam can be adjusted to the selected material here, wavelengths between approx. 0.3 μm and 2 μm usually being used. For metal particles of copper or aluminium, for example, a wavelength in the visible wavelength range (between approx. 380 nm and 780 nm), in particular in the green wavelength range (between approx. 490 nm and 575 nm), are selected, whereas, for silver, for example, a wavelength in the UV range (below 380 nm) may be selected. The laser power may be in the range of approx. 1 watt to 1000 watts in order to allow laser sintering or selective laser melting.
[0038] The volume ratio of the diamond particles 5 to the copper matrix 9 of the diamond-copper composite material 8 may be adjusted by appropriately selecting the ratio d1/d2 of the thicknesses d1, d2 of the layers 5 a, 6 a. In order to start out with the smoothest possible surface for producing the layer of the diamond-copper composite material 8 , contrary to the representation shown in FIG. 1 a - d , it is possible first of all to apply one or more layers 6 a of metal particles 6 to the substrate 3 and fuse these layers with the latter using laser radiation 7 .
[0039] In order to obtain a shaped body of the diamond-copper composite material 8 , the process described in connection with FIGS. 1 a - d can be repeated a number of times until the desired volume of the shaped body is achieved, as indicated in FIG. 1 d , in which, in a subsequent step, further diamond particles 6 are applied to the diamond-copper composite material 8 . If applicable, a structuring or an adaptation of the geometry or expansion of the layers in the XY direction to a desired geometry can be carried out by targeted, controlled closure of the openings in the device 4 for distributing the particles 5 , 6 .
[0040] A shaped body 10 comprising the diamond-copper composite material 8 having an essentially cuboid geometry is shown in FIG. 2 a . The shaped body 10 is introduced in a receptacle 11 of a base body 12 of copper which is part of a heat sink 13 . The shaped body 10 can (if applicable with the substrate) be introduced into the receptacle 11 as a prefabricated body. Alternatively, it is also possible for the shaped body 10 to be formed in situ in the receptacle 11 which serves as a mould in which the layers 5 , 6 are applied on top of one another.
[0041] As can likewise be seen in FIG. 2 a , the cuboid shaped body 10 has a plurality of layers 8 a, 8 b of the diamond-copper composite material 8 . A final layer 8 b on the upper side 14 of the shaped body 10 in the post-processing area has no diamond particles 5 here, i.e. through appropriate selection of the volume ratio of metal particles to diamond particles, the fusion forms, after infiltration, a sufficiently large layer thickness above the diamond particles in which practically no more diamond particles are present. It can thereby be assured that contact with a component in the form of a high-performance laser diode 15 (cf. FIG. 2 b ) applied directly on the upper surface 14 of the shaped body 10 serving as a positioning surface can be produced over the whole surface in order to guarantee effective thermal transfer. The direct connection of the component to the shaped body 10 can be made, for example, by bonding. It is also possible, as an alternative, for the component to be affixed to the shaped body 10 by a joining method using a joining agent, e.g. by soldering or adhesion.
[0042] In the example shown in FIG. 2 b , the shaped body 10 is soldered onto the upper surface 12 a of the cuboid base body 12 . A layer of metal particles is applied here, as a final layer 8 b, onto a layer 8 a of the carbon-metal composite material. The final layer 8 b has been irradiated with a laser during production in order to fuse the metal particles and join them to the layer 8 a of the carbon-metal composite material lying underneath it. The final layer 8 b is therefore, in this example, practically free of carbon particles and is particularly suitable for post-processing to achieve the lowest possible surface roughness.
[0043] It is self-evident that the thicknesses of the layers 8 a, 8 b of the diamond-copper composite material 8 can be selected differently in the thickness direction (Z), contrary to what is shown in FIGS. 2 a,b . If applicable, the metallic particles and/or the carbon particles used can also be varied from layer to layer. For example, a layer of diamond-silver composite material can follow a layer of diamond-copper composite material or vice versa.
[0044] As can be seen in FIG. 3 , the shaped body 10 and the laser diode 15 are formed on the edge of the base body 12 of the heat sink 13 of FIG. 2 b and serve to emit laser radiation in a direction that is pointing away from the heat sink 13 . The application of the laser diode 15 , which essentially consists of GaAs, onto the shaped body 10 of the diamond-copper composite material 8 is also particularly advantageous, inter alia, because both have comparable thermal expansion coefficients. It is self-evident that, instead of laser diodes, other components can also be cooled with the aid of the heat sink 13 , for example laser discs as used, for example, in a solid state laser. Since, in this case, the laser radiation is typically emitted in a direction perpendicular to the flat sides of the plate-shaped laser disc, the laser disc is not usually arranged on the edge of the heat sink but instead centrally on the heat sink.
[0045] It is likewise self-evident that the method shown in FIGS. 1 a - d , in particular the fusion of the layers 5 a, 6 a, may, if applicable, be supported by a pressure p that is above atmospheric pressure or by a temperature T that is above room temperature. The method described here, owing to the layered structure of the shaped body 10 , allows flexible adjustment of its properties in terms of geometry, surface quality, material behaviour, etc. The equipment used for producing the carbon-metal composite material is not complex and is therefore inexpensive to purchase. | A method for forming a carbon-metal composite material for a heat sink, comprising the following steps: applying at least one layer comprising carbon particles and at least one layer comprising metal particles on top of one another; and fusing of the layers by irradiating the layers with laser radiation to form the carbon-metal composite material. The invention also relates to a heat sink having a shaped body that comprises a plurality of layers, each layer containing carbon particles in a metal matrix. | 7 |
BACKGROUND OF THE DISCLOSURE
[0001] 1. Field of the Disclosure
[0002] The present disclosure generally relates to a managed pressure drilling system having a well control mode.
[0003] 2. Description of the Related Art
[0004] In wellbore construction and completion operations, a wellbore is formed to access hydrocarbon-bearing formations (e.g., crude oil and/or natural gas) by the use of drilling. Drilling is accomplished by utilizing a drill bit that is mounted on the end of a drill string. To drill within the wellbore to a predetermined depth, the drill string is often rotated by a top drive or rotary table on a surface platform or rig, and/or by a downhole motor mounted towards the lower end of the drill string. After drilling to a predetermined depth, the drill string and drill bit are removed and a section of casing is lowered into the wellbore. An annulus is thus formed between the string of casing and the formation. The casing string is temporarily hung from the surface of the well. A cementing operation is then conducted in order to fill the annulus with cement. The casing string is cemented into the wellbore by circulating cement into the annulus defined between the outer wall of the casing and the borehole. The combination of cement and casing strengthens the wellbore and facilitates the isolation of certain areas of the formation behind the casing for the production of hydrocarbons.
[0005] Deep water off-shore drilling operations are typically carried out by a mobile offshore drilling unit (MODU), such as a drill ship or a semi-submersible, having the drilling rig aboard and often make use of a marine riser extending between the wellhead of the well that is being drilled in a subsea formation and the MODU. The marine riser is a tubular string made up of a plurality of tubular sections that are connected in end-to-end relationship. The riser allows return of the drilling mud with drill cuttings from the hole that is being drilled. Also, the marine riser is adapted for being used as a guide means for lowering equipment (such as a drill string carrying a drill bit) into the hole.
SUMMARY OF THE DISCLOSURE
[0006] The present disclosure generally relates to a managed pressure drilling system having a well control mode. In one embodiment, a method of drilling a subsea wellbore includes drilling the subsea wellbore by: injecting drilling fluid through a tubular string extending into the wellbore from an offshore drilling unit (ODU); and rotating a drill bit disposed on a bottom of the tubular string. The drilling fluid exits the drill bit and carries cuttings from the drill bit. The drilling fluid and cuttings (returns) flow to a subsea wellhead via an annulus defined by an outer surface of the tubular string and an inner surface of the subsea wellbore. The returns flow from the subsea wellhead to the ODU via a marine riser. The method further includes, while drilling the subsea wellbore: measuring a flow rate of the drilling fluid injected into the tubular string; measuring a flow rate of the returns; comparing the returns flow rate to the drilling fluid flow rate to detect a kick by a formation being drilled; and exerting backpressure on the returns using a first variable choke valve. The method further includes, in response to detecting the kick: closing a blowout preventer of a subsea pressure control assembly (PCA) against the tubular string; and diverting the flow of returns from the PCA, through a choke line having a second variable choke valve, and through the first variable choke valve.
[0007] In another embodiment, a managed pressure drilling system includes: a first rotating control device (RCD) for connection to a marine riser; a first variable choke valve for connection to an outlet of the first RCD; a first mass flow meter for connection to an outlet of the first variable choke valve; a splice for connecting an inlet of the first variable choke valve to an outlet of a second variable choke valve; and a programmable logic controller (PLC) in communication with the first variable choke valve and the first mass flow meter. The PLC is configured to perform an operation, including, during drilling of a subsea wellbore: measuring a flow rate of returns using the first mass flow meter; comparing the returns flow rate to a drilling fluid flow rate to detect a kick by a formation being drilled; and exerting backpressure on the returns using the first variable choke valve. The operation further includes, in response to detecting the kick, diverting the returns through the second variable choke valve, the splice, and the first variable choke valve to alleviate pressure on the first variable choke valve.
[0008] In another embodiment, a method of drilling a subsea wellbore includes: drilling the subsea wellbore; and, while drilling the subsea wellbore: measuring a flow rate of drilling fluid injected into a tubular string having a drill bit; measuring a flow rate of drilling returns using a subsea mass flow meter; and comparing the returns flow rate to the drilling fluid flow rate to detect a kick by a formation being drilled. The method further includes, in response to detecting the kick: closing a blowout preventer of a subsea pressure control assembly (PCA) against the tubular string; and diverting the flow of returns from the PCA, through a choke line having a second variable choke valve, and through a first variable choke valve.
[0009] In another embodiment, a managed pressure drilling system includes: a first rotating control device (RCD) for connection to a marine riser; a first variable choke valve for connection to an outlet of the first RCD; a first mass flow meter for connection to an outlet of the first variable choke valve; a splice for connecting an inlet of the first variable choke valve to an outlet of a second variable choke valve; a second RCD for assembly as part of a subsea pressure control assembly; a subsea mass flow meter for connection to an outlet of the second RCD; and a programmable logic controller (PLC) in communication with the first variable choke valve and the first and second mass flow meters.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] So that the manner in which the above recited features of the present disclosure can be understood in detail, a more particular description of the disclosure, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this disclosure and are therefore not to be considered limiting of its scope, for the disclosure may admit to other equally effective embodiments.
[0011] FIGS. 1A-1C illustrate an offshore drilling system in a managed pressure drilling mode, according to one embodiment of the present disclosure.
[0012] FIGS. 2A and 2B illustrate the offshore drilling system in a managed pressure riser degassing mode. FIG. 2C is a table illustrating switching between the modes.
[0013] FIGS. 3A and 3B illustrate the offshore drilling system in a managed pressure well control mode. FIG. 3C illustrates operation of the PLC in the managed pressure well control mode.
[0014] FIGS. 4A and 4B illustrate the offshore drilling system in an emergency well control mode.
[0015] FIG. 5 illustrates a pressure control assembly (PCA) of a second offshore drilling system in a managed pressure drilling mode, according to another embodiment of the present disclosure.
DETAILED DESCRIPTION
[0016] FIGS. 1A-1C illustrate an offshore drilling system 1 in a managed pressure drilling mode, according to one embodiment of the present disclosure. The drilling system 1 may include a MODU 1 m, such as a semi-submersible, a drilling rig 1 r, a fluid handling system 1 h, a fluid transport system 1 t, and pressure control assembly (PCA) 1 p, and a drill string 10 . The MODU 1 m may carry the drilling rig 1 r and the fluid handling system 1 h aboard and may include a moon pool, through which drilling operations are conducted. The semi-submersible may include a lower barge hull which floats below a surface (aka waterline) 2 s of sea 2 and is, therefore, less subject to surface wave action. Stability columns (only one shown) may be mounted on the lower barge hull for supporting an upper hull above the waterline. The upper hull may have one or more decks for carrying the drilling rig 1 r and fluid handling system 1 h. The MODU 1 m may further have a dynamic positioning system (DPS) (not shown) or be moored for maintaining the moon pool in position over a subsea wellhead 50 .
[0017] Alternatively, the MODU 1 m may be a drill ship. Alternatively, a fixed offshore drilling unit or a non-mobile floating offshore drilling unit may be used instead of the MODU 1 m. Alternatively, the wellbore may be subsea having a wellhead located adjacent to the waterline and the drilling rig may be a located on a platform adjacent the wellhead. Alternatively, the wellbore may be subterranean and the drilling rig located on a terrestrial pad.
[0018] The drilling rig 1 r may include a derrick 3 , a floor 4 , a top drive 5 , and a hoist. The top drive 5 may include a motor for rotating 16 a drill string 10 . The top drive motor may be electric or hydraulic. A frame of the top drive 5 may be linked to a rail (not shown) of the derrick 3 for preventing rotation thereof during rotation 16 of the drill string 10 and allowing for vertical movement of the top drive with a traveling block 6 of the hoist. The frame of the top drive 5 may be suspended from the derrick 3 by the traveling block 6 . A Kelly valve 11 may be connected to a quill of a top drive 5 . The quill may be torsionally driven by the top drive motor and supported from the frame by bearings. The top drive 5 may further have an inlet connected to the frame and in fluid communication with the quill.
[0019] The traveling block 6 may be supported by wire rope 7 connected at its upper end to a crown block 8 . The wire rope 7 may be woven through sheaves of the blocks 6 , 8 and extend to drawworks 9 for reeling thereof, thereby raising or lowering the traveling block 6 relative to the derrick 3 . The drilling rig 1 r may further include a drill string compensator (not shown) to account for heave of the MODU 1 m. The drill string compensator may be disposed between the traveling block 6 and the top drive 5 (aka hook mounted) or between the crown block 8 and the derrick 3 (aka top mounted).
[0020] An upper end of the drill string 10 may be connected to the Kelly valve 11 , such as by threaded couplings. The drill string 10 may include a bottomhole assembly (BHA) 10 b and joints of drill pipe 10 p connected together, such as by threaded couplings. The BHA 10 b may be connected to the drill pipe 10 p, such as by threaded couplings, and include a drill bit 15 and one or more drill collars 12 connected thereto, such as by threaded couplings. The drill bit 15 may be rotated 16 by the top drive 5 via the drill pipe 10 p and/or the BHA 10 b may further include a drilling motor (not shown) for rotating the drill bit. The BHA 10 b may further include an instrumentation sub (not shown), such as a measurement while drilling (MWD) and/or a logging while drilling (LWD) sub.
[0021] The fluid transport system 1 t may include an upper marine riser package (UMRP) 20 , a marine riser 25 , a booster line 27 , a choke line 28 , and a return line 29 . The UMRP 20 may include a diverter 21 , a flex joint 22 , a slip (aka telescopic) joint 23 , a tensioner 24 , and a rotating control device (RCD) 26 . A lower end of the RCD 26 may be connected to an upper end of the riser 25 , such as by a flanged connection. The slip joint 23 may include an outer barrel connected to an upper end of the RCD 26 , such as by a flanged connection, and an inner barrel connected to the flex joint 22 , such as by a flanged connection. The outer barrel may also be connected to the tensioner 24 , such as by a tensioner ring (not shown).
[0022] The flex joint 22 may also connect to the diverter 21 , such as by a flanged connection. The diverter 21 may also be connected to the rig floor 4 , such as by a bracket. The slip joint 23 may be operable to extend and retract in response to heave of the MODU 1 m relative to the riser 25 while the tensioner 24 may reel wire rope in response to the heave, thereby supporting the riser 25 from the MODU 1 m while accommodating the heave. The riser 25 may extend from the PCA 1 p to the MODU 1 m and may connect to the MODU via the UMRP 20 . The riser 25 may have one or more buoyancy modules (not shown) disposed therealong to reduce load on the tensioner 24 .
[0023] The RCD 26 may include a docking station and a bearing assembly. The docking station may be submerged adjacent the waterline 2 s. The docking station may include a housing, a latch, and an interface. The RCD housing may be tubular and have one or more sections connected together, such as by flanged connections. The RCD housing may have one or more fluid ports formed through a lower housing section and the docking station may include a connection, such as a flanged outlet, fastened to one of the ports.
[0024] The latch may include a hydraulic actuator, such as a piston, one or more fasteners, such as dogs, and a body. The latch body may be connected to the housing, such as by threaded couplings. A piston chamber may be formed between the latch body and a mid housing section. The latch body may have openings formed through a wall thereof for receiving the respective dogs. The latch piston 63 p may be disposed in the chamber and may carry seals isolating an upper portion of the chamber from a lower portion of the chamber. A cam surface may be formed on an inner surface of the piston for radially displacing the dogs. The latch body may further have a landing shoulder formed in an inner surface thereof for receiving a protective sleeve or the bearing assembly.
[0025] Hydraulic passages may be formed through the mid housing section and may provide fluid communication between the interface and respective portions of the hydraulic chamber for selective operation of the piston. An RCD umbilical may have hydraulic conduits and may provide fluid communication between the RCD interface and a hydraulic power unit (HPU) via hydraulic manifold. The RCD umbilical may further have an electric cable for providing data communication between a control console and the RCD interface via a controller.
[0026] The bearing assembly may include a catch sleeve, one or more strippers, and a bearing pack. Each stripper may include a gland or retainer and a seal. Each stripper seal may be directional and oriented to seal against drill pipe 10 p in response to higher pressure in the riser 25 than the UMRP 20 . Each stripper seal may have a conical shape for fluid pressure to act against a respective tapered surface thereof, thereby generating sealing pressure against the drill pipe 10 p. Each stripper seal may have an inner diameter slightly less than a pipe diameter of the drill pipe 10 p to form an interference fit therebetween. Each stripper seal may be flexible enough to accommodate and seal against threaded couplings of the drill pipe 10 p having a larger tool joint diameter. The drill pipe 10 p may be received through a bore of the bearing assembly so that the stripper seals may engage the drill pipe 10 p. The stripper seals may provide a desired barrier in the riser 25 either when the drill pipe 10 p is stationary or rotating.
[0027] The catch sleeve may have a landing shoulder formed at an outer surface thereof, a catch profile formed in an outer surface thereof, and may carry one or more seals on an outer surface thereof. Engagement of the latch dogs with the catch sleeve may connect the bearing assembly to the docking station. The gland may have a landing shoulder formed in an inner surface thereof and a catch profile formed in an inner surface thereof for retrieval by a bearing assembly running tool. The bearing pack may support the strippers from the catch sleeve such that the strippers may rotate relative to the docking station. The bearing pack may include one or more radial bearings, one or more thrust bearings, and a self contained lubricant system. The bearing pack may be disposed between the strippers and be housed in and connected to the catch sleeve, such as by threaded couplings and/or fasteners.
[0028] Alternatively, the bearing assembly may be non-releasably connected to the housing. Alternatively, the RCD may be located above the waterline and/or along the UMRP at any other location besides a lower end thereof. Alternatively, the RCD may be assembled as part of the riser at any location therealong or as part of the PCA. Alternatively, an active seal RCD may be used instead.
[0029] The PCA 1 p may be connected to a wellhead 50 adjacently located to a floor 2 f of the sea 2 . A conductor string 51 may be driven into the seafloor 2 f. The conductor string 51 may include a housing and joints of conductor pipe connected together, such as by threaded couplings. Once the conductor string 51 has been set, a subsea wellbore 100 may be drilled into the seafloor 2 f and a casing string 52 may be deployed into the wellbore. The casing string 52 may include a wellhead housing and joints of casing connected together, such as by threaded couplings. The wellhead housing may land in the conductor housing during deployment of the casing string 52 . The casing string 52 may be cemented 101 into the wellbore 100 . The casing string 52 may extend to a depth adjacent a bottom of an upper formation 104 u. The upper formation 104 u may be non-productive and a lower formation 104 b may be a hydrocarbon-bearing reservoir.
[0030] Alternatively, the lower formation 104 b may be non-productive (e.g., a depleted zone), environmentally sensitive, such as an aquifer, or unstable. Although shown as vertical, the wellbore 100 may include a vertical portion and a deviated, such as horizontal, portion.
[0031] The PCA 1 p may include a wellhead adapter 40 b, one or more flow crosses 41 u,m,b, one or more blow out preventers (BOPs) 42 a,u,b, a lower marine riser package (LMRP), one or more accumulators 44 , and a receiver 46 . The LMRP may include a control pod 76 , a flex joint 43 , and a connector 40 u. The wellhead adapter 40 b, flow crosses 41 u,m,b, BOPs 42 a,u,b, receiver 46 , connector 40 u, and flex joint 43 , may each include a housing having a longitudinal bore therethrough and may each be connected, such as by flanges, such that a continuous bore is maintained therethrough. The bore may have drift diameter, corresponding to a drift diameter of the wellhead 50 . The flex joints 23 , 43 may accommodate respective horizontal and/or rotational (aka pitch and roll) movement of the MODU 1 m relative to the riser 25 and the riser relative to the PCA 1 p.
[0032] Each of the connector 40 u and wellhead adapter 40 b may include one or more fasteners, such as dogs, for fastening the LMRP to the BOPs 42 a,u,b and the PCA 1 p to an external profile of the wellhead housing, respectively. Each of the connector 40 u and wellhead adapter 40 b may further include a seal sleeve for engaging an internal profile of the respective receiver 46 and wellhead housing. Each of the connector 40 u and wellhead adapter 40 b may be in electric or hydraulic communication with the control pod 76 and/or further include an electric or hydraulic actuator and an interface, such as a hot stab, so that a remotely operated subsea vehicle (ROV) (not shown) may operate the actuator for engaging the dogs with the external profile.
[0033] The LMRP may receive a lower end of the riser 25 and connect the riser to the PCA 1 p. The control pod 76 may be in electric, hydraulic, and/or optical communication with a programmable logic controller (PLC) 75 and/or a rig controller (not shown) onboard the MODU 1 m via an umbilical 70 . The control pod 76 may include one or more control valves (not shown) in communication with the BOPs 42 a,u,b for operation thereof. Each control valve may include an electric or hydraulic actuator in communication with the umbilical 70 . The umbilical 70 may include one or more hydraulic and/or electric control conduit/cables for the actuators. The accumulators 44 may store pressurized hydraulic fluid for operating the BOPs 42 a,u,b. Additionally, the accumulators 44 may be used for operating one or more of the other components of the PCA 1 p. The PLC 75 and/or rig controller may operate the PCA 1 p via the umbilical 70 and the control pod 76 .
[0034] A lower end of the booster line 27 may be connected to a branch of the flow cross 41 u by a shutoff valve 45 a. A booster manifold may also connect to the booster line 27 and have a prong connected to a respective branch of each flow cross 41 m,b. Shutoff valves 45 b,c may be disposed in respective prongs of the booster manifold. Alternatively, a separate kill line (not shown) may be connected to the branches of the flow crosses 41 m,b instead of the booster manifold. An upper end of the booster line 27 may be connected to an outlet of a booster pump 30 b. A lower end of the choke line 28 may have prongs connected to respective second branches of the flow crosses 41 m,b. Shutoff valves 45 d,e may be disposed in respective prongs of the choke line lower end.
[0035] A pressure sensor 47 a may be connected to a second branch of the upper flow cross 41 u. Pressure sensors 47 b,c may be connected to the choke line prongs between respective shutoff valves 45 d,e and respective flow cross second branches. Each pressure sensor 47 a - c may be in data communication with the control pod 76 . The lines 27 , 28 and umbilical 70 may extend between the MODU 1 m and the PCA 1 p by being fastened to brackets disposed along the riser 25 . Each line 27 , 28 may be a flow conduit, such as coiled tubing. Each shutoff valve 45 a - e may be automated and have a hydraulic actuator (not shown) operable by the control pod 76 .
[0036] Alternatively, the umbilical may be extended between the MODU and the PCA independently of the riser. Alternatively, the valve actuators may be electrical or pneumatic.
[0037] The fluid handling system 1 h may include one or pumps 30 b,d, a gas detector 31 , a reservoir for drilling fluid 60 d, such as a tank, a fluid separator, such as a mud-gas separator (MGS) 32 , a solids separator, such as a shale shaker 33 , one or more flow meters 34 b,d,r, one or more pressure sensors 35 c,d,r, and one or more variable choke valves, such as a managed pressure (MP) choke 36 a and a well control (WC) choke 36 m. The mud-gas separator 32 may be vertical, horizontal, or centrifugal and may be operable to separate gas from returns 60 r. The separated gas may be stored or flared.
[0038] A lower end of the return line 29 may be connected to an outlet of the RCD 26 and an upper end of the return line may be connected to an inlet stem of a first flow tee 39 a and have a first shutoff valve 38 a assembled as part thereof. An upper end of the choke line 28 may be connected an inlet stem of a second flow tee 39 b and have the WC choke 36 m and pressure sensor 35 c assembled as part thereof. A first spool may connect an outlet stem of the first tee 39 a and an inlet stem of a third tee 39 c ( FIG. 2A ). The pressure sensor 35 r, MP choke 36 a, flow meter 34 r, gas detector 31 , and a fourth shutoff valve 38 d may be assembled as part of the first spool. A second spool may connect an outlet stem of the third tee 39 c and an inlet of the MGS 32 and have a sixth shutoff valve 38 f assembled as part thereof.
[0039] A third spool may connect an outlet stem of the second tee 39 b and an inlet stem of a fourth tee 39 d ( FIG. 2A ) and have a third shutoff valve 38 c assembled as part thereof. A first splice may connect branches of the first 39 a and second 39 b tees and have a second shutoff valve 38 b assembled as part thereof. A second splice may connect branches of the third 39 c and fourth 39 d tees and have a fifth shutoff valve 38 e assembled as part thereof. A fourth spool may connect an outlet stem of the fourth tee 39 d and an inlet stem of the fifth tee 39 e and have a seventh shutoff valve 38 g assembled as part thereof. A third splice may connect a liquid outlet of the MGS 32 and a branch of the fifth tee 39 e and have an eighth shutoff valve 38 h assembled as part thereof. An outlet stem of the fifth tee 39 e may be connected to an inlet of the shale shaker 33 .
[0040] A supply line 37 p,h may connect an outlet of the mud pump 30 d to the top drive inlet and may have the flow meter 34 d and the pressure sensor 35 d assembled as part thereof. An upper end of the booster line 27 may have the flow meter 34 b assembled as part thereof. Each pressure sensor 35 c,d,r may be in data communication with the PLC 75 . The pressure sensor 35 r may be operable to monitor backpressure exerted by the MP choke 36 a. The pressure sensor 35 c may be operable to monitor backpressure exerted by the WC choke 36 m. The pressure sensor 35 d may be operable to monitor standpipe pressure. Each choke 36 a,m may be fortified to operate in an environment where drilling returns 60 r may include solids, such as cuttings. The MP choke 36 a may include a hydraulic actuator operated by the PLC 75 via the HPU to maintain backpressure in the riser 25 . The WC choke 36 m may be manually operated.
[0041] Alternatively, the choke actuator may be electrical or pneumatic. Alternatively, the WC choke 36 m may also include an actuator operated by the PLC 75 .
[0042] The flow meter 34 r may be a mass flow meter, such as a Coriolis flow meter, and may be in data communication with the PLC 75 . The flow meter 34 r may be connected in the first spool downstream of the MP choke 36 a and may be operable to monitor a flow rate of the drilling returns 60 r. Each of the flow meters 34 b,d may be a volumetric flow meter, such as a Venturi flow meter, and may be in data communication with the PLC 75 . The flow meter 34 d may be operable to monitor a flow rate of the mud pump 30 d. The flow meter 34 b may be operable to monitor a flow rate of the drilling fluid 60 d pumped into the riser 25 ( FIG. 2B ). The PLC 75 may receive a density measurement of drilling fluid 60 d from a mud blender (not shown) to determine a mass flow rate of the drilling fluid 60 d from the volumetric measurement of the flow meters 34 b,d.
[0043] Alternatively, a stroke counter (not shown) may be used to monitor a flow rate of the mud pump and/or booster pump instead of the volumetric flow meters. Alternatively, either or both of the volumetric flow meters may be mass flow meters.
[0044] The gas detector 31 may be operable to extract a gas sample from the returns 60 r (if contaminated by formation fluid 62 ( FIG. 3C )) and analyze the captured sample to detect hydrocarbons, such as saturated and/or unsaturated C1 to C10 and/or aromatic hydrocarbons, such as benzene, toluene, ethyl benzene and/or xylene, and/or non-hydrocarbon gases, such as carbon dioxide and nitrogen. The gas detector 31 may include a body, a probe, a chromatograph, and a carrier/purge system. The body may include a fitting and a penetrator. The fitting may have end connectors, such as flanges, for connection within the first spool and a lateral connector, such as a flange for receiving the penetrator. The penetrator may have a blind flange portion for connection to the lateral connector, an insertion tube extending from an external face of the blind flange portion for receiving the probe, and a dip tube extending from an internal face thereof for receiving one or more sensors, such as a pressure and/or temperature sensor.
[0045] The probe may include a cage, a mandrel, and one or more sheets. Each sheet may include a semi-permeable membrane sheathed by inner and outer protective layers of mesh. The mandrel may have a stem portion for receiving the sheets and a fitting portion for connection to the insertion tube. Each sheet may be disposed on opposing faces of the mandrel and clamped thereon by first and second members of the cage. Fasteners may then be inserted into respective receiving holes formed through the cage, mandrel, and sheets to secure the probe components together. The mandrel may have inlet and outlet ports formed in the fitting portion and in communication with respective channels formed between the mandrel and the sheets. The carrier/purge system may be connected to the mandrel ports and a carrier gas, such as helium, argon, or nitrogen, may be injected into the mandrel inlet port to displace sample gas trapped in the channels by the membranes to the mandrel outlet port. The carrier/purge system may then transport the sample gas to the chromatograph for analysis. The carrier purge system may also be routinely run to purge the probe of condensate. The chromatograph may be in data communication with the PLC to report the analysis of the sample. The chromatograph may be configured to only analyze the sample for specific hydrocarbons to minimize sample analysis time. For example, the chromatograph may be configured to analyze only for C1-C5 hydrocarbons in twenty-five seconds.
[0046] In the drilling mode, the mud pump 30 d may pump drilling fluid 60 d from the drilling fluid tank, through the standpipe 37 p and Kelly hose 37 h to the top drive 5 . The drilling fluid 60 d may include a base liquid. The base liquid may be base refined or synthetic oil, water, brine, or a water/oil emulsion. The drilling fluid 60 d may further include solids dissolved or suspended in the base liquid, such as organophilic clay, lignite, and/or asphalt, thereby forming a mud.
[0047] The drilling fluid 60 d may flow from the Kelly hose 37 h and into the drill string 10 via the top drive 5 . The drilling fluid 60 d may flow down through the drill string 10 and exit the drill bit 15 , where the fluid may circulate the cuttings away from the bit and return the cuttings up an annulus 105 formed between an inner surface of the casing 101 or wellbore 100 and an outer surface of the drill string 10 . The returns 60 r (drilling fluid 60 d plus cuttings) may flow through the annulus 105 to the wellhead 50 . The returns 60 r may continue from the wellhead 50 and into the riser 25 via the PCA 1 p. The returns 60 r may flow up the riser 25 to the RCD 26 . The returns 60 r may be diverted by the RCD 26 into the return line 29 via the RCD outlet. The returns 60 r may continue from the return line 29 , through the open (depicted by phantom) first shutoff valve 38 a and first tee 39 a, and into the first spool. The returns 60 r may flow through the MP choke 36 a, the flow meter 34 r, the gas detector 31 , and the open fourth shutoff valve 38 d to the third tee 39 c. The returns 60 r may continue through the second splice and to the fourth tee 39 d via the open fifth shutoff valve 38 e. The returns 60 r may continue through the third spool to the fifth tee 39 e via the open seventh shutoff valve 38 g. The returns 60 r may then flow into the shale shaker 33 and be processed thereby to remove the cuttings, thereby completing a cycle. As the drilling fluid 60 d and returns 60 r circulate, the drill string 10 may be rotated 16 by the top drive 5 and lowered by the traveling block 6 , thereby extending the wellbore 100 into the lower formation 104 b.
[0048] Alternatively, the sixth 38 f and eighth 38 h shutoff valves may be open and the fifth 38 e and seventh 38 g shutoff valves may be closed in the drilling mode, thereby routing the returns 60 r through the MGS 32 before discharge into the shaker 33 .
[0049] The PLC 75 may be programmed to operate the MP choke 36 a so that a target bottomhole pressure (BHP) is maintained in the annulus 105 during the drilling operation. The target BHP may be selected to be within a drilling window defined as greater than or equal to a minimum threshold pressure, such as pore pressure, of the lower formation 104 b and less than or equal to a maximum threshold pressure, such as fracture pressure, of the lower formation, such as an average of the pore and fracture BHPs.
[0050] Alternatively, the minimum threshold may be stability pressure and/or the maximum threshold may be leakoff pressure. Alternatively, threshold pressure gradients may be used instead of pressures and the gradients may be at other depths along the lower formation 130 b besides bottomhole, such as the depth of the maximum pore gradient and the depth of the minimum fracture gradient. Alternatively, the PLC 75 may be free to vary the BHP within the window during the drilling operation.
[0051] A static density of the drilling fluid 60 d (typically assumed equal to returns 60 r; effect of cuttings typically assumed to be negligible) may correspond to a threshold pressure gradient of the lower formation 104 b, such as being equal to a pore pressure gradient. During the drilling operation, the PLC 75 may execute a real time simulation of the drilling operation in order to predict the actual BHP from measured data, such as standpipe pressure from sensor 35 d, mud pump flow rate from flow meter 34 d, wellhead pressure from any of the sensors 47 a - c, and return fluid flow rate from flow meter 34 r. The PLC 75 may then compare the predicted BHP to the target BHP and adjust the MP choke 36 a accordingly.
[0052] Alternatively, a static density of the drilling fluid 60 d may be slightly less than the pore pressure gradient such that an equivalent circulation density (ECD) (static density plus dynamic friction drag) during drilling is equal to the pore pressure gradient. Alternatively, a static density of the drilling fluid 60 d may be slightly greater than the pore pressure gradient.
[0053] During the drilling operation, the PLC 75 may also perform a mass balance to monitor for a kick ( FIG. 3C ) or lost circulation (not shown). As the drilling fluid 60 d is being pumped into the wellbore 100 by the mud pump 30 d and the returns 60 r are being received from the return line 29 , the PLC 75 may compare the mass flow rates (i.e., drilling fluid flow rate minus returns flow rate) using the respective counters/meters 34 d,r. The PLC 75 may use the mass balance to monitor for formation fluid 62 entering the annulus 105 and contaminating 61 r the returns 60 r or returns 60 r entering the formation 104 b. Upon detection of either event, the PLC 75 may shift the drilling system 1 into a managed pressure riser degassing mode. The gas detector 31 may also capture and analyze samples of the returns 60 r as an additional safeguard for kick detection.
[0054] Alternatively, the PLC 75 may estimate a mass rate of cuttings (and add the cuttings mass rate to the intake sum) using a rate of penetration (ROP) of the drill bit or a mass flow meter may be added to the cuttings chute of the shaker and the PLC may directly measure the cuttings mass rate. Alternatively, the gas detector 31 may be bypassed during the drilling operation. Alternatively, the booster pump 30 b may be operated during drilling to compensate for any size discrepancy between the riser annulus and the casing/wellbore annulus and the PLC may account for boosting in the BHP control and mass balance using the flow meter 34 b.
[0055] FIGS. 2A and 2B illustrate the offshore drilling system 1 in a managed pressure riser degassing mode. FIG. 2C is a table illustrating switching between the modes. To shift the drilling system 1 to degassing mode, the PLC 75 may halt injection of the drilling fluid 60 d by the mud pump 30 d and halt rotation 16 of the drill string 10 by the top drive 5 . The Kelly valve 11 may be closed. The top drive 5 may also be raised to remove weight on the bit 15 . The PLC 75 may then close one or more of the BOPs, such as annular BOP 42 a and pipe ram BOP 42 u, against an outer surface of the drill pipe 10 p. The PLC 75 may close the fifth 38 e and seventh 38 g shutoff valves and open the sixth 38 f and eighth 38 h shutoff valves. The PLC 75 may then open the first booster line shutoff valve 45 a and operate the booster pump 30 b, thereby pumping drilling fluid 60 d into a top of the booster line 27 . The drilling fluid 60 d may flow down the booster line 27 and into the upper flow cross 41 u via the open shutoff valve 45 a.
[0056] The drilling fluid 60 d may flow through the LMRP and into a lower end of the riser 25 , thereby displacing any contaminated returns 61 r present therein. The drilling fluid 60 d may flow up the riser 25 and drive the contaminated returns 61 r out of the riser 25 . The contaminated returns 61 r may be driven up the riser 25 to the RCD 26 . The contaminated returns 61 r may be diverted by the RCD 26 into the return line 29 via the RCD outlet. The contaminated returns 61 r may continue from the return line 29 , through the open first shutoff valve 38 a and first tee 39 a, and into the first spool. The contaminated returns 61 r may flow through the MP choke 36 a, the flow meter 34 r, the gas detector 31 , and the open fourth shutoff valve 38 d to the third tee 39 c. The contaminated returns 61 r may continue into an inlet of the MGS 32 via the open sixth shutoff valve 38 f. The MGS 32 may degas the contaminated returns 61 r and a liquid portion thereof may be discharged into the third splice. The liquid portion of the contaminated returns 61 r may continue into the shale shaker 33 via the open eighth shutoff valve 38 h and the fifth tee 39 e. The shale shaker 33 may process the contaminated liquid portion to remove the cuttings and the processed contaminated liquid portion may be diverted into a disposal tank (not shown).
[0057] As the riser 25 is being flushed, the gas detector 31 may capture and analyze samples of the contaminated returns 61 r to ensure that the riser 25 has been completely degassed. Once the riser 25 has been degassed, the PLC 75 may shift the drilling system 1 into managed pressure well control mode. If the event that triggered the shift was lost circulation, the returns 60 r may or may not have been contaminated by fluid from the lower formation 104 b.
[0058] Alternatively, if the booster pump 30 b had been operating in drilling mode to compensate for any size discrepancy, then the booster pump 30 b may or may not remain operating during shifting between drilling mode and riser degassing mode.
[0059] FIGS. 3A and 3B illustrate the offshore drilling system 1 in a managed pressure well control mode. To shift the drilling system 1 to the managed pressure well control mode, the PLC 75 may halt injection of the drilling fluid 60 d by the booster pump 30 b and close the booster line shutoff valve 45 a. The Kelly valve 11 may be opened. The PLC 75 may close the first shutoff valve 38 a and open the second shutoff valve 38 b. The PLC 75 may then open the second choke line shutoff valve 45 e and operate the mud pump 30 d, thereby pumping drilling fluid 60 d into a top of the drill string 10 via the top drive 5 . The drilling fluid 60 d may be flow down through the drill string 10 and exit the drill bit 15 , thereby displacing the contaminated returns 61 r present in the annulus 105 . The contaminated returns 61 r may be driven through the annulus 105 to the wellhead 50 . The contaminated returns 61 r may be diverted into the choke line 28 by the closed BOPs 41 a,u and via the open shutoff valve 45 e. The contaminated returns 61 r may be driven up the choke line 28 to the WC choke 36 m. The WC choke 36 m may be fully relaxed or be bypassed.
[0060] The contaminated returns 61 r may continue through the WC choke 36 m and into the first branch via the second tee 39 b. The contaminated returns 61 r may flow into the first spool via the open second shutoff valve 38 b and first tee 39 a. The contaminated returns 61 r may flow through the MP choke 36 a, the flow meter 34 r, the gas detector 31 , and the open fourth shutoff valve 38 d to the third tee 39 c. The contaminated returns 61 r may continue into the inlet of the MGS 32 via the open sixth shutoff valve 38 f. The MGS 32 may degas the contaminated returns 61 r and a liquid portion thereof may be discharged into the third splice. The liquid portion of the contaminated returns 61 r may continue into the shale shaker 33 via the open eighth shutoff valve 38 h and the fifth tee 39 e. The shale shaker 33 may process the contaminated liquid portion to remove the cuttings and the processed contaminated liquid portion may be diverted into a disposal tank (not shown).
[0061] FIG. 3C illustrates operation of the PLC 75 in the managed pressure well control mode. A flow rate of the mud pump 30 d for managed pressure well control may be reduced relative to the flow rate of the mud pump during the drilling mode to account for the reduced flow area of the choke line 28 relative to the flow area of the a riser annulus formed between the riser 25 and the drill string 10 . If the trigger event was a kick, as the drilling fluid 60 d is being pumped through the drill string 10 , annulus 105 , and choke line 28 , the gas detector 31 may capture and analyze samples of the contaminated returns 61 r and the flow meter 34 r may be monitored so the PLC 75 may determine a pore pressure of the lower formation 104 b. If the trigger event was lost circulation (not shown), the PLC 75 may determine a fracture pressure of the formation. The pore/fracture pressure may be determined in an incremental fashion, i.e. for a kick, the MP choke 36 a may be monotonically or gradually tightened 63 a,b until the returns are no longer contaminated with production fluid 62 . Once the back pressure that ended the influx of formation is known, the PLC 75 may calculate the pore pressure to control the kick. The inverse of the incremental process may be used to determine the fracture pressure for a lost circulation scenario.
[0062] Once the PLC 75 has determined the pore pressure, the PLC may calculate a pore pressure gradient and a density of the drilling fluid 60 d may be increased to correspond to the determined pore pressure gradient. The increased density drilling fluid may be pumped into the drill string 10 until the annulus 105 and choke line 28 are full of the heavier drilling fluid. The riser 25 may then be filled with the heavier drilling fluid. The PLC 75 may then shift the drilling system 1 back to drilling mode and drilling of the wellbore 100 through the lower formation 104 b may continue with the heavier drilling fluid such that the returns 64 r therefrom maintain at least a balanced condition in the annulus 105 .
[0063] Should the kick be severe such that the back pressure exerted by the MP choke 36 a approaches a maximum operating pressure of the first spool, the WC choke 36 m may be tightened (or brought online if bypassed) to alleviate pressure from the MP choke 36 a until the kick has been controlled. Since the WC choke 36 m is located upstream of the first spool, the chokes 36 a,m may operate in a serial fashion. The WC choke 36 m may function as a high pressure stage and the MP choke 36 a may function as a low pressure stage, thereby effectively increasing a maximum operating pressure of the first spool. Should tightening the chokes 36 a,m fail to control the kick, the PLC 75 may shift the drilling system into emergency well control mode.
[0064] FIGS. 4A and 4B illustrate the offshore drilling system 1 in an emergency well control mode. To shift the drilling system 1 to the emergency well control mode, the PLC 75 may halt injection of the drilling fluid 60 d by the mud pump 30 b and close the second 38 b and fourth 38 d shutoff valves and open the fifth shutoff valve 38 e. The PLC 75 may close a supply valve (not shown) for the mud pump 30 d from the drilling fluid tank and open a supply valve (not shown) for the mud pump 30 d from a kill fluid tank (not shown). The PLC 75 may then operate the mud pump 30 d, thereby pumping kill fluid 65 into a top of the drill string 10 via the top drive 5 . The kill fluid 65 may be flow down through the drill string 10 and exit the drill bit 15 , thereby displacing the contaminated drilling fluid present in the annulus 105 . The contaminated drilling fluid may be driven through the annulus 105 to the wellhead 50 . The contaminated drilling fluid may be diverted into the choke line 28 by the closed BOPs 41 a,u and via the open shutoff valve 45 . The contaminated drilling fluid may be driven up the choke line 28 to the WC choke 36 m.
[0065] The contaminated drilling fluid may continue through the WC choke 36 m and into the second spool via the second tee 39 b. The contaminated drilling fluid may flow into the second branch via the open third shutoff valve 38 c and fourth tee 39 d. The contaminated drilling fluid may bypass the first spool and continue into the inlet of the MGS 32 via the open fifth 38 e and 38 f sixth shutoff valves. The MGS 32 may degas the contaminated drilling fluid and a liquid portion thereof may be discharged into the third splice. The liquid portion of the contaminated drilling fluid may continue into the shale shaker 33 via the open eighth shutoff valve 38 h and the fifth tee 39 e. The processed contaminated liquid portion may be diverted into a disposal tank (not shown). The WC choke 36 m may be operated to bring the kick under control.
[0066] FIG. 5 illustrates a pressure control assembly (PCA) of a second offshore drilling system in a managed pressure drilling mode, according to another embodiment of the present disclosure. The second drilling system may include the MODU 1 m, the drilling rig 1 r, the fluid handling system 1 h, the fluid transport system 1 t, and a pressure control assembly (PCA) 201 p. The PCA 201 p may include the wellhead adapter 40 b, the one or more flow crosses 41 u,m,b, the blow out preventers (BOPs) 42 a,u,b, the LMRP, the accumulators 44 , the receiver 46 , a second RCD 226 , and a subsea flow meter 234 .
[0067] The second RCD 226 may be similar to the first RCD 26 . A lower end of the second RCD housing may be connected to the annular BOP 42 a and an upper end of the second RCD housing may be connected to the upper flow cross 41 u, such as by flanged connections. A pressure sensor may be connected to an upper housing section of the second RCD 226 . The pressure sensor may be in data communication with the control pod 76 and the second RCD latch piston may be in fluid communication with the control pod via an interface of the second RCD 226 .
[0068] A lower end of a subsea spool may be connected to an outlet of the second RCD 226 and an upper end of the spool may be connected to the upper flow cross 41 u. The spool may have first 245 a and second 245 b shutoff valves and the subsea flow meter 234 assembled as a part thereof. Each shutoff valve 245 a,b may be automated and have a hydraulic actuator (not shown) operable by the control pod 76 via fluid communication with a respective umbilical conduit or the LMRP accumulators 44 . The subsea flow meter 234 may be a mass flow meter, such as a Coriolis flow meter, and may be in data communication with the PLC 75 via the pod 76 and the umbilical 70 .
[0069] Alternatively, a subsea volumetric flow meter may be used instead of the mass flow meter.
[0070] In the drilling mode, the returns 60 r may flow through the annulus 105 to the wellhead 50 . The returns 60 r may continue from the wellhead 50 to the second RCD 226 via the BOPs 42 a,u,b. The returns 60 r may be diverted by the second RCD 226 into the subsea spool via the second RCD outlet. The returns 60 r may flow through the open second shutoff valve 245 b, the subsea flow meter 234 , and the first shutoff valve 245 a to a branch of the upper flow cross 41 u. The returns 60 r may flow into the riser 25 via the upper flow cross 41 u, the receiver 46 , and the LMRP. The returns 60 r may flow up the riser 25 to the first RCD 26 . The returns 60 r may be diverted by the first RCD 26 into the return line 29 via the first RCD outlet. The returns 60 r may continue from the return line 29 , through the open first shutoff valve 38 a and first tee 39 a, and into the first spool. The returns 60 r may flow through the MP choke 36 a, the flow meter 34 r, the gas detector 31 , and the open fourth shutoff valve 38 d to the third tee 39 c. The returns 60 r may continue through the second splice and to the fourth tee 39 d via the open fifth shutoff valve 38 e. The returns 60 r may continue through the third spool to the fifth tee 39 e via the open seventh shutoff valve 38 g. The returns 60 r may then flow into the shale shaker 33 and be processed thereby to remove the cuttings, thereby completing a cycle.
[0071] During the drilling operation, the PLC may rely on the subsea flow meter 234 instead of the surface flow meter 34 r to perform BHP control and the mass balance. The surface flow meter 34 r may be used as a backup to the subsea flow meter 234 should the subsea flow meter fail.
[0072] The degassing, well control, and emergency modes for the PCA 201 p may be similar to that of the PCA 1 p.
[0073] While the foregoing is directed to embodiments of the present disclosure, other and further embodiments of the disclosure may be devised without departing from the basic scope thereof, and the scope of the invention is determined by the claims that follow. | A method of drilling a subsea wellbore includes drilling the subsea wellbore and, while drilling the subsea wellbore: measuring a flow rate of the drilling fluid injected into a tubular string; measuring a flow rate of returns; comparing the returns flow rate to the drilling fluid flow rate to detect a kick by a formation being drilled; and exerting backpressure on the returns using a first variable choke valve. The method further includes, in response to detecting the kick: closing a blowout preventer of a subsea pressure control assembly (PCA) against the tubular string; and diverting the flow of returns from the PCA, through a choke line having a second variable choke valve, and through the first variable choke valve. | 4 |
BACKGROUND OF THE INVENTION
This invention relates generally to processes utilized within an enterprise, and more specifically to process development and integration of processes for use across multiple programs of an enterprise that provide products and/or services to customers.
Larger enterprises (e.g., governments, large corporations) frequently use hundreds, and possibly thousands, of different processes in order to perform a single service or manufacture a single product. Many of these processes, and the computing systems that support them, could be shared across many different services and/or products. However, without the ability to find and use common and similar processes across multiple product/service lines, to control variations in those processes, and to integrate those processes, each program must invent their own set of processes, and the computing systems that support the processes. These processes and systems must be maintained for the lifetime of the product/service which can be 50 years or more. This is extremely expensive. For example, a large corporation could have 100 major programs developing complex products, with each program having a lifetime of 50 years. The development and improvement of these products could consist of thousands of processes linked together into scenarios. Many of these processes rely on complex customized computing systems to support them. Typically, 75% or more of the processes and computing systems could be common (or common with minor variations) across the programs. If this commonality were not harnessed and managed, each of the programs would have to develop the processes and their supporting computing systems independently, and maintain them over their 50 year life spans. In the course of process maintenance, multiple versions of a particular process may come into existence.
Typically corporations define processes using a document-based or text-based approach, even if the documents are digitally-based flowcharts and descriptions. In this approach, the intelligence of the process is in the eye of the beholder. Specifically, users of these processes have to read and interpret the process steps, their inputs and outputs, and the roles and computing involved, in order retrieve or analyze any information about the process and interpretations by multiple users can vary. Simply put, a text-based process approach has no structure and must be interpreted by a human. A model-based definition has a defined structure and can be interpreted by software, which can then edit, analyze and integrate the process. In many of these text-based approaches, software-based analyses and integration cannot be enabled because the structure of the definitions is not well-defined or controlled. In order to integrate the processes used by a program (by connecting their inputs and outputs) and to manage their re-use and variation by other programs, the processes must be captured in computer-based business models. By modeling processes, they can be integrated (their inputs and outputs can be connected and their names and definitions made common and shared), the inputs/outputs can be defined precisely, common resource definitions for performing the process can be assigned, and the process can be analyzed to reduce inefficiencies within the process steps. The process execution can be simulated and resource usage can be tracked and even forecasted using such a model. In large-scale complex processes, it is not practical to integrate, analyze and manage the processes that are document-based. A model-based, computer-sensical representation is needed.
Processes typically are not managed enterprise-wide. Rather, the processes are managed in connection with delivering a certain service or in producing a particular end product, and not necessarily across services and across product lines. Such processes are not managed across service and product lines because, at least in part, it is extremely difficult to characterize, define and capture all information related to such processes.
SUMMARY OF THE INVENTION
Systems and methods are provided for modeling, integration and management complex business processes and their variations applied to large-scale enterprises with multiple product and service programs. Granular, stand-alone process definitions, comprised of constituent process steps, are stored in a library. Process definitions have variations, where the differences are controlled and managed, and each variation is versioned to allow for incremental improvement over time. Scenario definitions (also having variations and versions) are created by instancing (or using references to) the process definitions, as well as instances of other (smaller scope) scenarios. Scenarios are the definitions that are used by organizations. Inputs and outputs are used to join/link the internal process steps of a process definition. Process definitions are instanced into scenarios as the process steps of the scenario. Process definitions have unconnected external inputs/outputs. They can be connected only via the connections of their instantiation as process steps in scenarios. Moreover, each process step is associated with the roles of individuals, teams or organizations that perform the step and with the tools used to support its performance. The inputs and outputs are modeled/defined in a Business or Conceptual Object Model, in which the object is described and its attributes and relationships to other objects are defined. Process and scenario definitions, objects, roles and tools are categorized in a hierarchical index structures. These indices form the architecture for an organization's business model and enable the control of variation and the elimination of gaps and overlaps in the model. Ownership is assigned to the nodes in the indices to enable the control of variation and improvements via new versions.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing brief summary of the invention, as well as the following detailed description, is better understood when read in conjunction with the accompanying drawings, which are included by way of example, and not by way of limitation with regard to the claimed invention. In the accompanying drawings, the same or similar elements are labeled with the same reference numbers.
FIG. 1 depicts process definitions and related information.
FIG. 2 depicts scenario definitions and related information.
FIG. 3 depicts an overview of the operating environment for creating, manipulating, and utilizing the elements of the business model within the enterprise.
FIG. 4 depicts an exemplary operating environment in which one or more embodiments may be implemented.
FIG. 5 is a flowchart depicting a simplified method for creating a process scenario utilizing multiple process instances.
DETAILED DESCRIPTION OF THE INVENTION
Methods are provided which utilize a business model repository to provide central access to and use of elements of the business model. These elements are process, scenario, object, role, tool and applicability definitions. The business model architecture is composed of indices of each of the elements which serve to categorize, scope, bound the definitions and to identify gaps, overlaps and variations. Process definitions are instanced into scenarios and their inputs/outputs connected to form a large-scale executable business model for the corporation's organizations (e.g., programs, business units, functional disciplines). Processes and scenarios can be made applicable for different organizations, and can be varied and improved/evolved (versioned). By controlling the variation of processes and scenarios and by knowing which are used in the various organizations, the cost of developing and maintaining processes and their supporting computing systems, and for training people to execute them, can be greatly reduced. Process and scenario definitions can be utilized to automate employee training and be used with workflow tools to track performance of processes. Instancing of processes into scenarios allows multiple organizations within a large corporation to share common processes (and the expensive computing systems that enable them), and to control the degree of variation allowed. Utilizing computer-sensible models for processes and scenarios enables integration, analysis, simulations, optimization and deployment to organization in the form of automated work order initiation and statusing, and process-based work plans.
FIG. 1 depicts a process definition 10 element of the business model and its related information according to one or more embodiments of the invention. The diagram depicts this related information as objects, which may be implemented in a computer system as objects in an object-oriented programming language (e.g., Java or C++). Likewise, this information may be stored in relational database tables, object databases, and so forth.
Process definitions 10 may include a facility for allowing variations 12 of the process. For example, if a particular team within an organization uses a process with the same inputs and outputs, but does it in a manner different from a process definition stored in a library (shown in FIG. 3 ), then rather than create a new process definition, the team can create a variation of the existing process definition 10 . Each process definition has at least one variation 12 (the original or base definition) and may have multiple variations. Each variation has an applicability 14 , which identifies for which organization units/programs and for what points in time the definition is applicable. In addition, each variation of a process definition has at least one version 16 (the original or base) and can have multiple versions 16 are used to identify the improvement or evolution of the variation.
For a given process definition, variation, and version, the process step definitions 18 which together make up a process definition are defined and linked. Each variation and version of a process definition may have a different set of process steps, although at a minimum, different versions and variations of a process definition should all consume the same or similar inputs to produce the same or similar outputs. A process step definition includes references to the definitions of its inputs and outputs 20 , references to the definitions of roles 22 used to perform or supervise the needed actions and references to the definitions of tools 24 (and specific tool user interfaces for tool-dependent process steps) that support the execution of the process. The inputs/outputs reference definitions of classes and their inter-relationships in a business object model 80 . The objects within the model 80 are categorized in an index 81 that forms the business object architecture. Roles 22 include descriptions of skills or training required by a person to participate in the process definition step. Roles 22 are separately indexed 23 in order to facilitate the associated organization and hierarchy. Tools 24 include descriptions of tools (e.g., computing systems, machines, etc.) required to perform steps, and as with roles, they are separately indexed 25 . Other information may be stored with a process definition step, such as, a textual description of the process, estimates of time taken, special handling information, and so forth. Business object, role and tool definitions are also versioned to identify and manage their evolution/improvement.
Process definitions 10 are categorized by multiple indices 30 , 32 , each providing a different hierarchical way of slicing and accessing a collection of process definitions. These indices comprise the process architecture. Primary index 30 is organized by taxonomy/similarity of function across the organization. It serves as the primary mechanism for controlling commonality and variation, and for detecting gaps in the process structure. Nodes in the index structure can have designated “owners” who can control the process definitions and the variations. All the process definitions associated with the manufacture of products, for example, may be in one category, and subcategories beneath that may further divide process definitions based on product family and product. Secondary index 32 may index processes by the types of inputs, outputs, tools, or rules they use or produce, or by owner. There may be any number of secondary indices. All process definitions are required to be referenced by the Primary index 30 . Secondary indices 32 may reference the Primary index 30 at any node in the index (and then to all definitions in the category) or they can point to specific definitions, or both, and they can have their own unique categories at levels higher than their references to the primary index.
Process definitions 10 are of two types, each of which may follow its own conventions. The tool-dependent process definition 40 may provide very specific information about how to perform a process using a specific set of tools (e.g., machinery, equipment, computer software). Such a process definition can be more instructive for employees, but may not be useful to other groups within an organization who may rely on different tools. These definitions are related to specific user interfaces to the tool. Tool-independent process definition 42 provides a general description of a process without delving into implementation details. Such a definition may be more useful throughout an organization. Each of these definitions may include “utility” processes 44 , which are common low level definitions that can be used in many process definitions. These utility processes are instanced into other process definitions as “utility instance” process steps 60 .
Process definition steps 18 may include multiple types of process steps, each of which may follow its own conventions. An in-place process step 50 is the most common type of step, where the action to be performed on the inputs is described within the process step. An external process step 52 uses an external reference to an entity external to the library (shown in FIG. 3 ) in order to provide information about the process step. In-place process steps can be simple or complex. A simple process step 54 involves a single action be performed, whereas a complex process step 56 involves multiple actions, which are defined by decomposing the step into multiple lower level process steps. These lower level steps may themselves be complex, but eventually simple steps, which don't decompose, are defined. A branch 58 is an evaluation or decision be made in order to proceed through the process definition to downstream steps. A simple process step 54 in a tool-independent definition may decompose into several simple or complex steps in the tool-dependent definition 40 . A utility instance process step 60 is a reference to a utility process definition. In one embodiment, it is a virtual process step that is connected to other process steps via its inputs/outputs, just like all of types of process steps, but the definition of the step is obtained through the reference to the source definition for the utility process definition. The utility instance process step definition may contain certain instance-specific information: the instance name, instance description, and instance-specific sub-class names for roles, tools and I/O. The connectivity 70 of the process step definitions 18 is specified by aligning/connecting the inputs and outputs 20 of the process step definitions 18 , or, for the case of the utility instance process step 60 , the instance-specific sub-classes of the referenced utility process definition's inputs/outputs.
FIG. 2 depicts scenario definitions 100 and related information according to one or more embodiments of the invention. As with process definitions 10 , scenario definitions 100 can have variations 102 having an associated applicability 104 and versions 106 . In one embodiment, scenario definitions 100 are indexed and cataloged to form the scenario architecture. Scenario definitions are the same as process definitions except they have “instanced” process steps 108 (process steps that reference and use other definitions) and cannot have “in-place” process steps. There are two types of these instanced steps. The first type is instanced process definitions 110 , which are virtual copies of process definitions that retain a relationship to their parent process definitions 10 . The second type is instanced scenario definitions 112 , which is a virtual copy of another scenario definition (of a smaller scope). Both of these types of instanced scenario step definitions, as with the utility instance process step definitions of a process definition, contain the reference to the source definition and the instance-specific information: the instance name, instance description, instance-specific sub-class names for roles, tools and I/O. Finally, a branch 114 can be placed as a scenario step definition, allowing a decision or evaluation to be made in order to select among paths to other scenario step definitions. As with process definitions, a scenario definition can be tool dependent 120 or tool independent 122 . However, unlike process definitions, the-dependent definitions are generated views. Process definitions are the only definitions for which tool-dependent views may be authored, since those are the most detailed definitions and since scenario definitions, at their most detail, merely instance process definitions. So, the tool-dependent view of a scenario definition merely retrieves/assembles the most detailed definitions of its instances, in accordance with the scenario's tool-independent definition. Scenarios are also hierarchically categorized in a scenario index 130 , again similar to process definitions. Scenario step definitions inherit their role definitions 22 , inputs and outputs 20 , and tool definitions 24 from the definitions being instanced within, except where sub-classes of those definitions have been specified as part of the instance-specific information. The connectivity of the scenario step definitions 108 is specified by aligning/connecting the inputs and outputs 20 of the instanced definitions ( 110 or 112 ) and their instance-specific sub-classes, and of the branches 114 .
FIG. 3 depicts an overview of the creation, manipulation, and utilization of the elements of the business model (process, scenario, object, role tool/computing system, and applicability definitions and inter-relationships), and their related architecture indices of an organization according to one or more embodiments of the invention. Here, library 200 , sometimes referred to herein as business model data base, stores process definitions 10 and their indices 30 and 32 , and scenario definitions 100 and their index 130 , object model 80 and its index 81 , role definitions 22 and their index 23 , tool definitions 24 and their index 25 , applicability definitions 14 and their index 15 , and all their inter-relationships (as shown in FIG. 1 ). Each of these objects are used in concert for creating new definitions and variations, creating new versions, controlling and managing the creation process and access to the definitions, and deploying the definitions for use.
As utilized herein, business models include the detailed, structured, open, and computer-sensible definitions describing how a business is to operate. These models include definitions of what products the business produces, what processes it uses to produce them, what roles are used to perform the process, what tools are used to support performance of the process and how they are used, and where and when the processes are performed. The business model architecture includes the specific elements of a business model that set the structure, scope, and context for the detail design of the business model. Contents of this architecture includes primary and secondary process indices containing, for example, process category/subcategory names and descriptions, and the names of processes in the categories; a thread index, containing, for example, thread category/sub-category names and names of threads in the categories; a business object index containing, for example, business object category/sub-category names and descriptions and names of objects in the categories; a role index containing, for example, role category/sub-category names and descriptions and names of roles in the categories; and a computing system index containing, for example, computing system category/sub-category names and descriptions and names of computing systems in the categories, and an applicability index containing, for example, category/sub-category names and descriptions and names of the enterprises organizational units to which the process and thread definitions may apply and of the points in time for which they apply.
The described business models include business model elements, including, but are not limited to, process models (primary and secondary process indices (process categories), process definitions (for the processes in the index), thread indices, and thread definitions (linked sub-threads and/or process instances with references to process definitions)); business object models ((product/data model), business object indices, conceptual/business object model (COM/BOM): product definitions, attributes definitions, product relationship definitions for all input and output products, their sub-classes and super-classes); role and organization definitions (role index, role descriptions (individual, team and formal organizations), and an organization structure); a computing system definition including a computing system index and application and delivery system architecture and detail definitions.
As further described herein, it is important to understand that while each specific element of the business model is configuration-controlled as a unit, inter-relationships between the elements require that this library be managed in an integrated manner by a single Business Model Data Manager.
In FIG. 3 , process designer 210 creates process definitions 10 utilizing computer software. These process definitions mirror, describe, or otherwise inform about actual processes (or processes that will be implemented). Such processes may include steps for assembling a product or subassembly, steps for providing a particular service, and so forth. For example user 210 may create a process definition 10 which explains one method for assembling a portion of an airplane fuselage. In creating process definition 10 , process designer 210 creates and links multiple process steps.
Each process step of the process definition 100 requires one or more inputs, involves one or more actions to be performed, and produce any number of outputs. Inputs and outputs may comprise physical objects or substances, waste products, specific information, forms for completion, and so forth, or conceptual objects such as the design of a system. A process definition 10 represents the packaging of one or more process steps 18 (shown in FIG. 1 ) connected in a sequence defined by their I/O connections 70 (shown in FIG. 1 ). In order to share definitions of inputs and outputs across process steps (and across process definitions), they are defined as business objects in a Business or Conceptual Object Model 80 . Process definitions 10 can also include branches, where a decision must be made, and different process steps followed depending on the outcome.
Scenario designer 211 may further modify business model elements stored in the business model database of library 200 . Scenario designer 211 may instance process definitions in sequences, creating scenario 100 . Scenario 100 may include an instance of process definition 10 , in combination with instances of other process definitions and scenarios, with branches. An “instance” is a virtual copy (not a physical copy, which could be modified once copied) of process definition 10 which references its parent process definition. Scenarios can thus be used to package instances of other scenarios and process definitions, joining outputs to inputs, and creating ever larger chains of process steps and decisions. In this manner, a large process can be broken down into ever smaller sub-processes, making the large process more manageable. In addition, process definitions can be re-used as instances in various scenarios, creating efficiencies within an organization.
Before new process definitions and scenarios are defined in detail, they are named and categorized or indexed in order to determine if similar, usable/modifiable definitions exist already and to simplify finding and reusing the objects. Both process definitions and scenarios have their own index. Multiple indices 205 can be utilized for either process definitions or scenarios, allowing users multiple ways to access the objects. For example, process definitions may be categorized based on product family, or on inputs utilized, and so forth. Each index 205 may further be a hierarchical index, where categories can have subcategories, which can also have subcategories, and so forth. Business objects (the inputs/outputs of process steps), roles and tools (e.g., computing systems used to support a process step) are also indexed.
In addition to categorical indices 205 , process and scenario definitions 10 and 100 within the business model database of library 200 are provided a trait referred to as applicability 14 (shown in FIG. 1 and in FIG. 2 ) as described above. The applicability trait is a statement that declares, for example, which organizations and for what timeframes a given process definition 10 or scenario definition 100 is applicable. For example, if the manufacturing department creates a generic process for retooling an assembly line, the applicability can be set to the department. If the process only applies to a specific type of assembly line, then applicability may be further limited. Likewise, if the research and development department creates a generic process for designing a new mechanical part, the process can be made applicable within the department. Applicability may also be set to required, such that all users within the applicable group must use the particular process definition for the relevant task. Furthermore, applicability may also enable or disable the ability to create variations of process or scenario definitions at a certain level within an organization. For example, an organization may wish to allow some groups to vary a process (e.g., due to the use of different tools), whereas others may be constrained to using the process as defined. Ultimately, an organization may desire to maximize the commonality of processes throughout the organization while allowing for variation and specialization where they make sense (e.g., where product-type differences dictate some difference in the process of designing or manufacturing of the product.
Once scenarios have been created, embodying instances of processes (or other smaller-scope scenarios), this information can be utilized to automatically generate training systems for employees 212 , 213 . A training presentation or reference document can be generated showing the steps required to perform a particular process definition or step. In addition, the information embodied in a database of library 200 can be used in conjunction with a workflow system to track and manage the flow of work in the process. A workflow system may prompt employees 212 , 213 to perform particular process steps (e.g., via an email message or electronic pager), or it may accept work updates from employees as process steps are performed. Ultimately, by sharing processes across an organization, significant savings may be realized by avoiding the cost of reinventing processes. Furthermore, using shared processes to adhere an organization to certain computing systems (as specified in the shared processes) can avoid the high cost of selecting, acquiring, tailoring, and maintaining disparate computing systems.
Other uses of the objects in database of library 200 include the creation of metrics (e.g., key performance indicators (KPIs)) which can then be tracked. For example, as an employee uses a process definition to create multiple outputs, in conjunction with a workflow system, the quantity and efficiency of output can be tracked. Such a database may be also be used to create test processes and track test performance.
Library 200 may be housed within computers (shown in FIG. 4 ) as one or more physical databases, flat files, or other storage structures. They are stored in a single logical repository; if physically distributed, those repositories are linked. A business model application (shown in FIG. 4 ) can access library 200 , and may be stored on computers, and may access the library locally on the same machine, or remotely over a network connection. The types of business model applications include, for example, modeling applications, analysis and simulation applications, view definition and generation applications, business model data management applications, deployment applications such as workflow and process-based planning applications, as well as business model development planning applications.
FIG. 4 depicts an exemplary operating environment in which one or more embodiments of the invention may be implemented. The operating environment may comprise computing device 400 which may work alone or with other computing devices 418 . Computing device 400 may comprise memory storage 404 coupled to processing unit 402 . Any suitable combination of hardware, software, and/or firmware may be used to implement memory 404 , processing unit 402 and other components. By way of example, memory 404 , processing unit 402 , and/or other components may be implemented within computing device 400 as shown, or may be implemented in combination with other computing devices 418 . The systems, devices, and processors shown are used merely as examples.
Generally, program modules may include routines, programs, components, data structures, and other types of structures that perform particular tasks or implement particular abstract data types. Moreover, embodiments may be practiced with other computer system configurations, including hand-held devices, multiprocessor systems, microprocessor-based or programmable consumer electronics, minicomputers, mainframe computers, set-top boxes, and so forth. Embodiments may also be practiced in distributed computing environments where tasks are performed by other computing devices 418 that are linked through a communications network. In a distributed computing environment, program modules may be located in both local and remote memory storage devices.
Embodiments, for example, may be implemented as a computer process or method (e.g., in hardware or in software), a computing system, or as an article of manufacture, such as a computer program product or computer readable media. The computer program product may be a computer storage media readable by a computer system and encoded with a computer program of instructions for executing a process on computing device 400 . The computer program product may also be a propagated signal on a carrier readable by a computing system and subsequently stored on a computer readable medium on computing device 100 .
With reference to FIG. 4 , the embodiment shown may include a computing device, such as computing device 400 . In a basic configuration, computer device 400 may include at least one processing unit 402 , and memory 404 . Depending on the configuration of the computer device, memory 404 may be volatile (e.g., Random Access Memory (RAM)), non-volatile (e.g., Read-Only Memory (ROM), Flash, etc.), or some combination thereof. Memory 404 may serve as a storage location for operating system 405 , one or more applications 406 , and may include program data 407 , as well as other programs. In one embodiment, applications 406 may include business model application 420 .
Although the basic computing device configuration is contained within dashed-line box 408 , computing device 400 may include additional features and functionality. For example, computing device 400 may include additional data storage components, including both removable storage 409 (e.g., floppy disks, memory cards, compact disc (CD) ROMs, digital video discs (DVDs), external hard drives, universal serial bus (USB) key drives, etc.) and non-removable storage 410 (e.g., magnetic hard drives).
Computer storage media may include media implemented in any method or technology for storage of information, including computer readable instructions, data structures, program modules, or other data. Memory 404 , removable storage 409 , and non-removable storage 410 are all examples of computer storage media. Further examples of such media include RAM, ROM, electrically-erasable programmable ROM (EEPROM), flash memory, CD-ROM, DVD, cassettes, magnetic tape, magnetic disks, and so forth. Any such computer storage media may be accessed by components which are a part of computing device 400 , or which are external to computing device 400 and connected via a communications link (e.g., Bluetooth, USB, parallel, serial, infrared, etc.). Computing device 400 may also include input devices 412 , such as keyboards, mice, pens, microphone, touchpad, touch-display, etc. Output devices 414 may include displays, speakers, printers, and so forth. Additional forms of storage, input, and output devices may be utilized.
Computing device 400 may also include one or more communication connections 416 which allow the computing device to communicate with other computing devices 418 , such as over a network (e.g., a local area network (LAN), the Internet, etc.). Communication media, in the form of computer readable instructions, data structures, program modules, or other data in a modulated data signal, may be shared with and by device 400 via communication connection 416 . Modulated data signal may mean a signal that has one or more of its characteristics set or changed in such a manner as to encode information in the signal, and may include a modulated carrier wave or other transport mechanism. Communication connection 416 may be comprised of hardware and/or software enabling either a wired (e.g., Ethernet, USB, Token Ring, modem, etc.) or wireless (e.g., WiFi, WiMax, cellular, acoustic, infrared, radio frequency (RF), etc.) communication conduit with other devices 418 .
FIG. 5 depicts a method for modeling a scenario definition utilizing multiple process definitions according to one or more embodiments of the invention. At step 501 , a first process definition is received for entry into a library. The process definition may include one or more process steps, the steps being related to each other by the tying of outputs to inputs. The process definition may also include information about human roles required to complete the various steps in the process. When initially created, the process steps associated with the definition may be associated via a default variation and a default version. Subsequent variations and versions of the process definition may necessitate additional versions and variations being created. At step 502 , a second process definition is received for entry into a library of processes.
At step 503 , a scenario definition is received in which multiple processes and scenarios can be assembled. At step 504 , an instance of the first process definition is added to the scenario definition created in step 503 . This may have been indicated to business model application 420 ( FIG. 4 ) via a user interface, in which a user selected a process definition, possibly via drag and drop, or simple selection from a list of process definitions. An instance of a process definition may reference a particular version and variation with no instance-specific information. However, an instance of a process or scenario definition may reference the stored version and variation of an object, coupled with instance specific attributes or variables. By instancing the process definition, changes can be made to the original process definition (in the form of a new version) without necessarily jeopardizing existing scenarios which are using the process. Scenario owners may be offered the opportunity to change or upgrade the instance of a process definition when a new version is created, for example. At step 505 , the second process definition is also instanced into the scenario definition. And at step 506 , the output or outputs of the instance of the first process definition are associated with one or more of the inputs of the second process definition.
To provide an example of the scenario and process definitions being created in this method, consider the manufacturing of a large passenger aircraft. The millions of parts required to produce a complete aircraft must be assembled using thousands of processes. Moreover, designing such an aircraft involves thousands of processes as well, from designing a part to producing assembly designs, and so forth. In this example, the first process definition may be a process to assemble an aileron subassembly. The second process definition may be a process to assemble a wing. The output of the first process (along with other process outputs), the aileron subassembly, would be an input to the wing assembly second process, which would produce its own output. Instances of these two assembly processes may be combined into a scenario for wing assembly, as provided by the method described in FIG. 5 above. The scenario may then be instanced into other parent assembly scenarios, ultimately producing a scenario for assembling the entire aircraft. When a subsequent aircraft is designed, process and scenario definitions can be re-instanced into new scenarios, saving work involved in process design. Likewise, if several different types of aircraft use the same general process to assemble an aileron subassembly, each aircraft may be able to create variations for specific implementation details which vary between designs. In addition, the process definition can be versioned (e.g., when a new more efficient process is determined), allowing scenario consumers of instances of the process definition to maintain the older version of the process, or possibly “upgrade” to the new process version.
For the large enterprise, as objects are placed in library 200 ( FIG. 3 ), they may be shared for approval before they can be instanced and used. An approval system for process and scenario definitions may work with or mirror the functionality of a workflow system. Moreover, such a system may involve multiple levels of approval, requiring plans for process or scenario definitions to first be approved before any work is done on actually creating the definitions. Such a system may assist in the cataloging of business needs, the determination of requirements which summarize those needs, as well as the process and scenario definitions which will help fulfill the requirements.
While the invention has been described in terms of various specific embodiments, those skilled in the art will recognize that the invention can be practiced with modification within the spirit and scope of the claims. | Tools and methods allow an enterprise to define a set of processes and create scenarios which link and integrate combinations of processes. In addition, both processes and scenarios can be categorized, enabling re-use of existing definitions and easing subsequent scenario building. Processes and scenarios both allow variations which are stipulated to have a certain applicability in terms of organizations within the enterprise and time-frame. The variations can be evolved and improved over time via versions. Subsequently designed process scenarios can be tested and released for use in an organization and used to drive work planning, initiation and status reporting. | 6 |
RELATED APPLICATIONS
This application is a continuation of U.S. application Ser. No. 11/200,026 filed 10 Aug. 2005 which itself is a continuation of Patent Cooperation Treaty application No. PCT/CA03/001975 filed 24 Dec. 2003 and a continuation-in-part of U.S. application Ser. No. 10/360,740 filed 10 Feb. 2003.
TECHNICAL FIELD
The invention relates to mounting prefabricated construction units in apertures in building envelopes. Particular embodiments of the invention have application to a system for mounting windows in apertures in a building envelope.
BACKGROUND
Today most windows are provided in the form of a unit which includes one or more glass panes mounted in a frame. The glass panes typically comprise sealed double-or triple-glazed panels. The frame is typically made of vinyl or another plastic material which does not conduct heat well although some aluminum-framed window units are still sold. The frame of each window unit typically includes a broad flange which projects in a lateral direction and extends around the periphery of the window unit. Other types of prefabricated construction units such as doors, vents and sunlights may have similar flanges.
A typical wood frame building has a frame of wooden members which includes apertures for prefabricated construction units such as windows, doors, vents, sunlights and the like. An appropriately-sized construction unit is received in each of the apertures with the flange overlapping with and abutting the outside of the building frame. The construction units are typically secured in place by placing a few screws or nails through the flange into the building frame on each side of the construction units.
One disadvantage of the way that construction units are currently installed is that a person must be outside of the building to install the construction units. This is especially problematic for window units, since window apertures may be located well above ground level. Windows in such locations are often installed by a person standing on a ladder. This can be dangerous, especially if the weather is windy or during winter conditions.
Another disadvantage of the way that construction units are currently installed is that many buildings have a waterproofing membrane applied to their exterior. Puncturing the membrane with screws or nails reduces the effectiveness of the membrane.
There is a need for more efficient ways to install construction units.
SUMMARY OF THE INVENTION
This invention provides prefabricated construction units with tabs which can be used to affix the construction units in place in the apertures of a building wall from inside the building. One aspect of the invention provides a clip for use in affixing a construction unit to a building structure. The clip comprises a thin tab having a transverse groove at an exterior end thereof for receiving a flange of a frame of the construction unit and at least one attachment point at an interior end thereof. The attachment point may comprise, for example, an aperture and/or a projection which projects from the tab. The clip can be affixed to a frame by inserting a flange of the frame into the groove. The attachment point can be used to affix the clip to a building structure.
Another aspect of the invention provides a clip for affixing a construction unit to a building structure. The clip comprises an exterior end and an interior end. The exterior end of the clip has means for affixing the clip to a frame of a construction unit. The interior end of the clip comprises means for affixing the interior end of the clip to a building structure. Various means for performing these functions are described below.
A still further embodiment of the invention provides a construction unit comprising a frame; a flange projecting laterally from the frame around a periphery of the frame; and, a plurality of tabs projecting from the frame in an interior direction. Each of the tabs is attached to the frame at an exterior end thereof and comprises at least one attachment point at an interior end thereof. The attachment point comprises an aperture and/or a projection which projects from the tab.
Yet another aspect of the invention provides methods for installing a construction unit in an aperture in a wall of a building structure. One such method comprises affixing a plurality of tabs to a frame of a construction unit with the tabs projecting interiorly from the frame; placing the construction unit into the aperture; and, affixing an interior end of the tabs to the building structure.
Further aspects of the invention and features of specific embodiments of the invention are described below.
BRIEF DESCRIPTION OF THE DRAWINGS
In drawings which illustrate non-limiting embodiments of the invention,
FIG. 1 is a partially cut-away isometric view of a window being installed in a building structure with the use of mounting clips according to the invention;
FIG. 2 is an isometric view of a window mounting clip according to a particular embodiment of the invention;
FIG. 3 is a cross-section through a portion of a window installed in an aperture in a building frame using window mounting clips of the type shown in FIG. 2 ;
FIGS. 4A , 4 B and 4 C are isometric views of end portions of window mounting clips according to alternative embodiments of the invention.
FIG. 5A is an isometric view of a window mounting clip according to another embodiment of the invention;
FIG. 5B is a cross-section through a portion of a window installed in an aperture in a building frame using window mounting clips of the type shown in FIG. 5A ;
FIGS. 6A and 6B are respectively cross-sectional and isometric views of a window mounting clip according to another alternative embodiment of the invention; and
FIGS. 7A and 7B are cross-sectional views of window mounting clips according to still further embodiments of the invention.
DESCRIPTION
Throughout the following description, specific details are set forth in order to provide a more thorough understanding of the invention. However, the invention may be practiced without these particulars. In other instances, well known elements have not been shown or described in detail to avoid unnecessarily obscuring the invention. Accordingly, the specification and drawings are to be regarded in an illustrative, rather than a restrictive, sense.
FIG. 1 shows a portion of the frame 10 of a typical wood-framed structure. Frame 10 comprises wooden studs 11 covered on the exterior by sheathing 12 . Frame 10 includes an aperture 13 surrounded by wooden framing members 14 for receiving a window unit 15 . Window unit 15 includes a window frame 16 , which may be made from any suitable material, and a glass panel 18 .
Window unit 15 is illustrated as being four-sided. The invention may also be used with construction units having other shapes such as triangular, round, semi-circular, polygonal etc.
Window frame 16 includes a flange 20 which projects in a lateral direction around the periphery of window frame 16 . Aperture 13 is smaller than the outer dimension of flange 20 and is dimensioned to receive window frame 16 while flange 20 bears against the exterior surface of sheathing 12 .
This invention provides clips 30 . Each clip 30 has an exterior end 32 adapted to engage window frame 16 and an interior end 34 adapted to be fastened to building frame 10 from the inside of building frame 10 . Clips 30 are used by affixing one or more clips 30 to each side of window frame 16 . In the example shown in FIG. 1 , two clips 30 are affixed to each side of window frame 16 . For larger window units, three or more clips 30 might be affixed to each side of window frame 16 . In most cases, two or more clips 30 will be affixed to each side of window frame 16 .
In the illustrated embodiment of the invention clips 30 attach to flange 20 . FIG. 2 shows a clip 30 in greater detail. Clip 30 is formed from a strip of any suitable material, such as steel, strong plastic, or the like. The material of clip 30 is preferably resilient. In some embodiments, clip 30 may be coated with a coating layer (not shown) which is thermally non-conductive relative to the material of clip 30 . For example, such a coating layer may comprise rubber, plastic, vinyl, fiberglass or the like. Such a coating layer may help to reduce or prevent condensation on the surface(s) of clip 30 . In some embodiments, a coating layer may be provided on the contact surface(s) of clip 30 . Interior end 34 of clip 30 comprises one or more apertures 36 which can receive fasteners, such as screws or nails, to affix interior end 34 to building structure 10 . Apertures 36 constitute one possible means for affixing interior end 34 to a building structure.
Exterior end 32 of clip 30 is bent to define a deep groove 38 . As shown in FIG. 3 , groove 38 is deep enough to receive flange 20 of window frame 16 . The portions 39 A and 39 B of clip 30 on either side of groove 38 are preferably (but not necessarily) resiliently biased toward one another, so that clip 30 tends to grip flange 20 . Inwardly-angled teeth 40 ( FIG. 2 ) may optionally be provided on one or both sides of groove 38 . After flange 20 is received in groove 38 , teeth 40 bite into flange 20 and resist any forces which might tend to pull flange 20 out of groove 38 .
An outer side 42 of groove 38 may be tapered so that it is easy to guide flange 20 into groove 38 . As flange 20 is introduced into side 42 of groove 38 , it tends to wedge portions 39 A and 39 B apart so that flange 20 is held securely in groove 38 .
Clip 30 is preferably (but not necessarily) bent at a location intermediate ends 32 and 34 . The bend defines a fulcrum 44 . As shown in FIG. 3 , when end 34 is fastened to structure 10 , clip tends to pivot about fulcrum 44 so that end 32 is biased into even firmer engagement with flange 20 . Clip 30 is preferably resiliently flexible. As end 34 is fastened to building structure 10 by fasteners, such as nails 46 , clip 30 is straightened.
Providing a bend in clip 30 also facilitates affixing clip 30 to building structure 10 with fasteners (for example nails or screws) which are angled in an inward direction. When such fasteners are tightened, clips 30 are drawn inwardly and pull window frame 16 firmly into the aperture.
FIGS. 4A , 4 B and 4 C illustrate a number of alternative configurations for interior end 34 . In each of FIGS. 4A , 4 B and 4 C, end 34 includes a number of projections 48 which project from clip 30 and which may be driven into framing members 14 ( FIG. 1 ) when clip 30 is affixed to a window frame 16 . In the illustrated embodiments, projections 48 are integral with the material of the body of clip 30 and are formed by bending flaps of the material of clip 30 . Projections 48 may be triangular, as shown in FIGS. 4A and 4B , or may have more elongated shapes, as shown in FIG. 4C , or may have other shapes. The embodiments of FIGS. 4A and 4C comprise both apertures 36 and projections 48 . Projections 48 may project at right angles to end 34 of clip 30 . In alternative embodiments, projections 48 capable of use for affixing end 34 to building structure 10 could comprise separate elements affixed to end 34 in any suitable manner. For example, suitable projections 48 could be spot-welded to end 34 . Projections affixed to end 34 provide an alternative means for affixing end 34 to a building structure 10 .
In the embodiment of FIG. 4C , projections 48 are located near the ends of flexible fingers 49 .
Projections 48 are not necessarily large enough to permanently affix ends 34 to a building structure 10 . In some embodiments, projections 48 may be used to temporarily hold ends 34 to the building structure until screws or nails are inserted through apertures 36 .
FIGS. 5A and 5B illustrate a clip 30 according to another embodiment of the invention. In the embodiment of FIGS. 5A and 5B , clip 30 comprises a protuberance 33 which projects upwardly from a surface of middle portion 31 . When window unit 15 is mounted in a building aperture 23 using clips 30 of the type shown in FIGS. 5A and 5B , protuberances 33 create a gap 37 between the uppermost edge 14 A of framing members 14 and a lower edge 16 A of window frame 16 . Gap 37 extends between adjacent clips 30 on the same side of window unit 15 . Gap 37 may be used to facilitate the exchange of gas and/or moisture between the exterior and interior of a building, and to facilitate the escape of gas and/or moisture from between the layers of a building wall.
Although FIG. 5B depicts clip 30 in use on a lower side of window unit 15 , it will be appreciated that clips incorporating protuberance 33 may be used to create gaps 37 on other sides of window unit 15 . Protuberance 33 depicted in FIGS. 5A and 5B represents one possible embodiment of a protuberance that will create a gap 37 between window frame 16 and framing members 14 . Some alternative embodiments comprise a plurality of protuberances on each clip 30 . Some alternative embodiments comprise one or more protuberances that project in the opposing direction from an opposite surface of middle portion 31 (i.e. towards framing members 14 ). In other alternative embodiments, clip 30 comprises one or more protuberances which project in an interior direction from a surface of portion 39 B to provide a gap between window flange 20 (and portion 39 B of clip 30 ) and the exterior surface of sheathing 12 . Such a gap may communicate with gap 37 to facilitate the exchange of gas and/or moisture. In still other alternative embodiments, the relative thickness of middle portion 31 (and/or portion 39 B) of clip 30 are increased, so that clip 30 can act as a spacer to provide gaps between a window frame and adjacent structures.
FIGS. 6A and 6B are respectively cross-sectional and isometric views of a clip 130 according to a further alternative embodiment of the invention. Clip 130 comprises a plurality of pieces, which include exterior piece 130 A, interior piece 130 B and thermal isolation coupling 137 . As shown in FIGS. 6A and 6B , exterior piece 130 A preferably comprises exterior end 132 , including portions 139 A, 139 B which define deep groove 138 . Interior piece 130 B preferably comprises interior end 134 and middle portion 131 . Thermal isolation coupling 137 couples interior piece 130 B to exterior piece 130 A and provides thermal insulation therebetween. Thermal isolation coupling 137 is fabricated from a material (or materials) that are thermally insulating relative to the material of exterior and interior pieces 130 A, 130 B. For example, exterior and interior pieces 130 A, 130 B may comprise steel or some other metallic alloy., while thermal isolation coupling 137 may comprise rubber, plastic, vinyl, fiberglass or the like. Thermal isolation of interior piece 130 B from exterior piece 130 A reduces the possibility of moisture condensing on interior piece 130 B due to cold temperatures experienced by exterior piece 130 A.
In the illustrated embodiment; thermal isolation coupling 137 comprises grooves 141 A, 141 B for respectively receiving the ends of exterior and interior pieces 130 A, 130 B. Preferably, thermal isolation coupling 137 is fabricated from a resilient material, such that when exterior and interior pieces 130 A, 130 B are inserted into grooves 141 A, 141 B, the deformation of grooves 141 A, 141 B acts to hold the ends of exterior and interior pieces 130 A, 130 B in-place (i.e. to couple the ends of exterior and interior pieces 130 A, 130 B to thermal isolation coupling 137 ). In alternative embodiments, adhesive, rivets and/or other suitable fasteners may be used to help couple the ends of exterior and interior pieces 130 A, 130 B to thermal isolation coupling 137 . Thermal isolation coupling 137 may be molded in place around the ends of pieces 130 A, 130 B. Exterior and interior pieces 130 A, 130 B may be coated with a coating layer (not shown) which is thermally non-conductive relative to the material of exterior and interior pieces 130 A, 130 B. Such a coating layer may also help reduce or prevent condensation on the surface(s) of exterior and interior pieces 130 A, 130 B.
It can be appreciated that the use of this invention can significantly simplify the installation of prefabricated construction units in a building, especially where one would need a ladder, scaffold, man lift or the like to reach the locations where-the construction units will be installed from the exterior of the building. A worker can affix clips 30 according to the invention to a construction unit and then, from inside the structure, orient the construction unit at an angle to the aperture in which the construction unit will be installed and pass the construction unit through the aperture to the outside of the structure. Still working from inside the structure, the worker can then draw the construction unit into place in the aperture and fasten the construction unit in place by affixing interior ends 34 of clips 30 to the structure. If necessary, shims may be installed around the frame of the construction unit to properly align the construction unit in the aperture.
A further advantage of the invention is realized in situations where a waterproofing membrane or the like is applied to the exterior of building frame 10 . Prior art systems for securing construction units to building structures typically require the membrane to be punctured by nails or screws in the area adjacent to aperture 13 . In some cases building codes prohibit fastening the lower sides of construction units in ways which result in the membrane being punctured. Sometimes windows are installed with no fasteners on their lower sides for this reason. The result can be that the lower sides of the windows can move, especially in windy weather. The use of clips 30 according to the invention allows the membrane to remain intact and still permits securing the lower side of window units and other construction units by way of one or more clips 30 .
It can be appreciated that clips 30 having an exterior end 32 as described above can be affixed to a construction unit frame with minimal tools and without the need to drill holes in the frame or to modify the window or door frame in other respects.
Where a component (e.g. a member, tab, fastener etc.) is referred to above, unless otherwise indicated, reference to that component (including a reference to a “means”) should be interpreted as including as equivalents of that component any component which performs the function of the described component (i.e., that is functionally equivalent), including components which are not structurally equivalent to the disclosed structure which performs the function in the illustrated exemplary embodiments of the invention.
As will be apparent to those skilled in the art in the light of the foregoing disclosure, many alterations and modifications are possible in the practice of this invention without departing from the spirit or scope thereof. For example:
While the above detailed description relates primarily to window units, it is to be understood that clips according to the invention may equally be used to secure other types of construction units, such as door units, vent units, sunlight units and the like, into appropriately sized apertures in a building frame. In some embodiments, a layer of deformable, elastomeric material (not shown) may be attached to one (or both) of the surfaces of middle portion 31 of clip 30 . Such deformable, elastomeric layer(s) may make clip 30 more malleable, thereby facilitating installation of clip 30 and preventing clip 30 from accidentally damaging window unit 15 or frame 10 . Such deformable, elastomeric layer(s) may also help to accommodate warpage in the shape of the edges of window unit 15 and/or framing members 14 . Similar deformable, elastomeric layer(s) may be used with all of the above-discussed clip embodiments. In some embodiments, thermal isolation coupling 137 may have a different shape than the one depicted in FIGS. 6A and 6B and may be coupled to exterior and interior pieces 130 A, 130 B in a different manner than that depicted in FIGS. 6A and 6B . FIGS. 7A and 7B respectively depict cross-sectional views of window mounting clips according to still further embodiments of the invention. Clip 130 of FIG. 7A comprises an exterior piece 130 A and an interior piece 130 B. Pieces 130 A, 130 B are coupled to one another by a thermal isolation coupling 137 ′ that is T-shaped in cross section, with flanges 150 A, 150 B that extend over pieces 130 A, 130 B. Thermal isolation coupling 137 ′ may be coupled to exterior and interior pieces 130 A, 130 B using adhesive, rivets and/or other suitable fasteners (not shown). Those skilled in the art will appreciate that T-shaped thermal isolation coupling 137 ′ may be inverted (relative to pieces 130 A, 130 B) such that flanges 150 A, 150 B extend under pieces 130 A, 130 B. In the embodiment of FIG. 7B , exterior and interior pieces 130 A, 130 B are coupled together by a relatively flat-shaped thermal isolation coupling 137 ″. Thermal isolation coupling 137 ″ comprises exterior and interior ends 152 A, 152 B, which extend respectively over pieces 130 A, 130 B. Thermal isolation coupling 137 ″ may be coupled to pieces 130 A, 130 B using adhesive, rivets and/or other suitable fasteners (not shown). Those skilled in the art will appreciate that flanges 152 A, 152 B of thermal isolation coupling 137 ″ may alternatively extend below pieces 130 A, 130 B or both above and below pieces 130 A, 130 B. Thermal isolation couplings 137 ′, 137 ″ are preferably thermally non-conductive relative to the material of exterior and interior pieces 130 A, 130 B.
Accordingly, the scope of the invention is to be construed in accordance with the substance defined by the following claims. | A clip is provided for affixing a construction unit to a building structure. The clip comprises: a generally planar middle portion, an exterior portion located on an exterior side of the middle portion and an interior portion located on an interior side of the middle portion; the exterior portion comprising a groove at an exterior end of the clip for receiving a construction unit flange, the groove having a generally U-shaped cross-section, the groove defined at least in part by a pair of generally parallel groove portions and a base portion connecting the groove portions at a base of the groove, the base of the groove spaced apart from an opening of the groove; the middle portion extending from an interior side of groove toward the interior portion; and the interior portion at an interior end of the clip, the interior portion extending from the middle portion at an obtuse angle to define a fulcrum at a junction between the middle portion and the interior portion. | 4 |
[0001] This application claims priority to U.S. patent application Ser. No. 10/831,951, filed May 29, 2004, and U.S. Provisional Patent No. 60/465,000 filed Apr. 25, 2003, the entire disclosures of which are herein incorporated by reference in their entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates generally to the field of storage and dispensing apparatus.
[0004] 2. Description of Related Art
[0005] Gift wrapping is a notoriously burdensome, messy, and disfavored chore, primarily because very little advancement has been made in the field of gift wrap storage and dispensing devices. During the holiday season, for example, it is common to use multiple rolls of wrapping paper, bows, ribbons of varying prints and designs. Further, there are typically numerous packages to be wrapped at a given time. A large working area is, therefore, required in order to work efficiently and effectively. In most instances, an open floor space is the only area large enough to accommodate the gift wrapping projects of ordinary scale. The traditional approach to wrapping gifts, therefore, entails sitting on the floor amongst what, before long, becomes a cluttered and disorganized mess of partially unraveled paper, accessories and trash. The inconvenience and awkwardness of having to bend, stretch, reach, and crawl across the floor to access wrapping paper and accessories inevitably leads to frustration and tiredness. Moreover, as almost anyone familiar with this situation knows, it is almost certain that scissors and tape will be misplaced or buried among the scattered mess, thereby posing a risk of injury.
[0006] FIG. 1 is a perspective view of the gift wrap apparatus;
[0007] FIG. 2 is a 2 is a top view of the container of the gift wrap apparatus;
[0008] FIG. 3 is a cut-away top view of the container of the gift wrap apparatus;
[0009] FIG. 4 is a cross section of the gift wrap apparatus;
[0010] FIG. 5 is a cut-away view of the ratchet-system;
[0011] FIG. 6 is a perspective view of the gift wrap apparatus;
[0012] FIG. 6A is a perspective view of the blade unit;
[0013] FIG. 7 is a second perspective view of the gift wrap apparatus;
[0014] FIG. 8 is a third perspective view of the gift wrap apparatus; and
[0015] FIG. 9 is cut-away view of the ratchet-system.
SUMMARY OF THE INVENTION
[0016] The present invention provides, in a preferred embodiment, an improved gift wrap system and storage device, wherein wrapping paper and wrapping accessories are accessible for use from their stored position in the apparatus. The apparatus comprises a container which houses a plurality of dowels for holding rolls of wrapping paper. The wrapping paper is dispensed through openings in the container adjacent to the dowels. Once the desired amount of wrapping paper is dispensed, flaps positioned on the sides of the container fold down against wrapping paper to hold it firmly against the side of the container, and to keep excess wrapping paper from being dispensed once the desired amount of wrapping paper for a particular gift has been dispensed. A cutting device, such as a serrated edge or the like, is positioned on the flap. Wrapping paper extending beyond the flap on the container is grasped and pulled against the cutting device to cut the paper to the desired length. The container is preferably rotatably affixed to a base so that the user can, while remaining in one position, rotate the container so that the desired wrapping paper inside container is easily accessible.
[0017] The apparatus includes a lid, which is rotatably positioned on a flange extending perpendicularly from the container, and a dispenser housing extending from the inside wall of the lid. Removable dispenser wheels are provided which are designed to be inserted into the center of rolls of ribbon or tape. The dispenser wheels have pegs extending perpendicularly from both sides, which are dimensioned to fit into corresponding recesses in the dispenser housing. Lid 9 has openings in its side wall through which wrapping accessories, e.g. tape and ribbon, are dispensed. A cutting device, such as a serrated edge or the like, is positioned at each opening for cutting the wrapping accessories. Lid 9 preferably has an opening at its top end, which may be covered by a door.
[0018] Rotation of the container and the lid is facilitated by, for example ball bearings positioned between the flange and the lid. Locking mechanisms, such as a levers which, when engaged, apply frictional force to the container or base, or a ratchet-like system, are used to prevent container from rotating when directional force is applied to the container, such as when dispensing or cutting the wrapping paper.
[0019] In another embodiment apparatus includes an second, inner-container, which is positioned inside the outside container and the dowels. The inner container can be used as a trash receptacle or for storing additional rolls of wrapping paper. The top side of the inner container is open to the opening in the lid, such that trash or wrapping paper can be inserted in the inner container through the opening in the lid, without having to remove the lid.
DETAILED DESCRIPTION OF THE INVENTION
[0020] The present invention provides an improved gift wrap apparatus designed to eliminate the inadequacies of conventional gift wrap and storage devices. In particular, the invention is directed to a gift wrap apparatus that conveniently stores multiple rolls of wrapping paper and wrapping accessories while, at the same time, making the wrapping paper accessible without having to remove the wrapping paper or accessories from the apparatus. The apparatus, therefore, greatly simplifies the process of wrapping gifts, and eliminates many of the inconveniences and attendant dangers of traditional wrapping apparatus and techniques.
[0021] In a preferred embodiment, as exemplified in FIG. 1 , the present invention provides a gift wrap apparatus 10 comprising a container 20 having at least one side wall 30 , and at least one dowel 40 extending from the floor 50 of container 20 for receiving rolls of wrapping paper 25 . Side wall 30 has at least one opening 60 or slits through which wrapping paper is dispensed. Openings 60 , therefore, are preferably positioned proximate to dowels 40 . Container 2 is rotatably situated on a base 70 , the rotation being facilitated, for example, by ball bearings 80 or other known rotating means. Container 20 includes a removable lid 90 , which in a preferred embodiment is itself rotatably situated among an annular flange 100 extending perpendicularly from side wall 30 . The rotation of lid 90 is also being facilitated by, for example, ball bearings 80 or other known rotation means. Container 20 and lid 90 are, therefore, separately rotatable with respect to one another. At least one first locking mechanism (not shown) is positioned on base 7 and at least one second locking mechanism (not shown) is positioned on container 20 . The first locking mechanism, for example, can be a lever disposed on base 70 , which when frictionally engaged with container 20 , prevents rotation of container 20 with respect to base 70 . Similarly, the second locking mechanism can be a lever positioned on the upper portion of side wall 30 , which when frictionally engaged with lid 90 , prevents rotation of lid 90 with respect to container 20 . In another embodiment, the first locking mechanism and second locking mechanism can comprise a standard ratchet-like system 110 , which permits rotation in one direction, but prevents rotation in an opposite direction. In essence, any known locking mechanism which prevents rotation of container 20 or lid 90 can be used.
[0022] On the exterior of container 20 , adjacent to each opening 60 is a flap 120 coupled to container 20 , by for example, a hinge mechanism 130 , for securing wrapping paper dispensed through opening 60 to the exterior of side wall 30 of container 20 . A cutting device 140 , e.g. a serrated edge, is positioned on flap 120 . In one embodiment cutting device 140 is positioned on the outside edge 142 of flap 120 . In another embodiment, cutting device 140 is a blade unit 150 coupled to the outside face of flap 120 and, in accordance with this embodiment, has a vertically positioned opening 152 which serves as a track for blade unit 150 . Blade unit 150 is spring 154 -loaded and comprises a blade 156 coupled to a press tab 158 . Press tab 158 is positioned on the outside face of flap 120 , with the blade 156 projecting into opening 152 . In a relaxed position, press tab 158 rests above flap 120 , such that blade 156 extends only partially through opening 152 . When flap 120 is closed upon wrapping paper 25 , pressure is applied to press tab 158 such that blade 156 extends fully through opening to cut wrapping paper 25 . While maintaining pressure on press tab 158 , blade unit 156 is then pushed downward along opening 152 , to cut wrapping paper 25 from its top edge to its bottom edge.
[0023] With flaps 120 open, wrapping paper 25 is dispensed through openings 60 in side wall 30 of container 20 , until the desired length of wrapping paper 25 has been dispensed. Flaps 120 are then folded downward to tightly secure wrapping paper 25 against side wall 30 of container 20 . Wrapping paper 25 extending beyond outside of flap 120 is grasped and pulled against cutting device 140 on flap 120 , so as to cut wrapping paper 25 to the desired length. A lead portion of wrapping paper 25 , having an approximate width of flap 120 , will remain under flap 120 . The downward force applied to wrapping paper 25 by flap 120 , or the resistance applied by the aforementioned ratchet system 110 , which is applied in the direction opposite to that in which wrapping paper 25 is pulled against cutting device 140 , prevents excess wrapping paper 25 from being dispensed. When flap 120 is opened, the lead portion of wrapping paper 120 will be exposed, which will serve as the grasping portion for the next section of wrapping paper 25 to be dispensed. Flap 120 , therefore, always maintains portion of wrapping paper 25 outside of container 10 , so that wrapping paper 25 does not have to be fed through openings 60 each time a new piece of wrapping paper 25 is cut. Wrapping paper 25 does not have to be removed from its stored position on the dowels 40 in container 10 prior to use. When a roll of wrapping paper 25 is depleted, the cardboard sleeve upon which wrapping paper 25 is wound is simply removed from dowel 40 and discarded. A new roll of wrapping paper 25 is placed on dowel 40 in its place. The number of rolls of wrapping paper 25 available for dispensing at any one time is determined by the number of dowels 40 in container 20 . Dowels 40 are preferably of a diameter smaller than the diameter of the sleeve upon which wrapping paper 25 is wound, so that wrapping paper 25 rolls can be easily placed on and removed from dowel 40 . Dowels 40 can be of any length, but where there is a lid 90 , preferably not so long as to hinder the placement of lid 90 onto container 20 . It is contemplated that wrapping paper 25 of different styles and different prints, for example, will be placed on the various dowels 40 , so as to offer and provide access to a wide variety of wrapping paper 25 .
[0024] Lid 90 preferably contains an accessory dispenser 160 for holding, storing, and dispensing gift wrap accessories 164 , such as ribbon and tape, extending from the interior of lid 90 . In a preferred embodiment, dispenser 160 , comprising a housing unit 162 having recesses 166 for receiving a dispensing wheel 168 . Dispensing wheel 168 is positioned within the open center portion of a roll of tape or ribbon and has a tight tolerance with respect thereto, such that frictional force maintains dispensing wheel 168 within the open center portion of the roll of tap or ribbon. Extending laterally from dispensing wheel 168 are pegs 169 , dimensioned to fit and be secured within recesses 166 of housing unit 160 . Lid 90 has openings 170 or slits therein through which gift wrapping accessories 164 , e.g., positioned within housing unit 160 can be dispensed. A cutting device (not shown), e.g. a serrated edge, razor blade, etc. is positioned on the lid 90 at the position of opening 170 for cutting the accessory 164 dispensed through said opening 170 .
[0025] Apparatus 10 is particularly advantageous in that its user or users, from a single position, has access to multiple rolls of wrapping paper 25 which, in ordinary instances, will vary in style and design. Apparatus 10 is, therefore, a significant improvement over conventional gift wrap apparatus, in that apparatus 10 serves simultaneously as a storage device, and a gift wrap and accessory dispenser. Moreover, unlike the conventional methods of gift wrapping, for example, wherein one sits on the floor amidst wrapping paper strewn about, apparatus 10 , eliminates the inherent discomforts (e.g. backaches), dangers (e.g. cuts and/or strained muscles), frustrations (e.g. lost scissors) and clutter attendant with these conventional methods. For instance, apparatus 10 can be conveniently situated next to its user, whether on the floor and adjacent to a table top, for example, leaving ample working space for gift wrapping. Container 20 is rotated to position the wrapping paper 25 of interest adjacent to its user. The user then simply dispenses the desired amount of wrapping paper 25 and cuts it using cutting device 140 . When user wants to use a different style or type of wrapping paper 25 , without having to reach or reposition, user simply rotates container 20 , so that the desired roll of wrapping paper 25 is positioned adjacent to the user. Similarly, lid 90 is rotated, so that the desired gift wrapping accessory 164 is positioned adjacent to user. Accessory 164 is dispensed through opening 170 and cut at the desired length using cutting device. Since lid 90 and container 20 are separately rotatable with respect to each other, user can have any combination of wrapping paper 25 and accessory 164 positioned immediately adjacent user. Where, for example, user wishes to use a different wrapping paper 25 , but continue using a particular accessory 164 , user can disengage the first locking mechanism (not shown) and freely rotate container 20 until the next desired wrapping paper 25 is positioned adjacent user. Likewise, where user wishes to use a different accessory 164 , but wants to continue using a particular wrapping paper 25 , user can disengage second locking mechanism (not shown) and freely rotate lid 90 , until the next desired accessory 164 is positioned adjacent user. It is further contemplated that container 20 can be positioned on its side, such that wrapping paper 25 is dispensed parallel to surface upon which a gift is wrapped. With container 20 on its side, a predetermined amount of wrapping paper 25 can be dispensed, and a gift placed on the paper to determine exactly how much wrapping paper 25 is necessary to wrap the gift. Once the desired length of wrapping paper 25 is determined, wrapping paper 25 can be cut using cutting device 140 .
[0026] In another preferred embodiment, a second, inner container 180 is housed within container 20 and lid 90 has an opening 182 positioned on its topside. Dowels 40 are preferably positioned between inner container 180 and container 20 . Inner container 180 preferably has a handle 184 to facilitate its removal from container 20 . It is contemplated that inner container 180 can be used to store additional rolls of wrapping paper 25 which are not positioned on dowels 40 , or used as a trash receptacle for receiving paper scraps, etc. Opening 182 in lid 90 is preferably positioned in-line with opening of inner container 180 , such that rolls of wrapping paper, trash, etc. can be placed into inner container 180 without having to remove lid 90 . When used as a trash receptacle, for example, inner container 180 can be removed from container 20 , emptied, and reinserted into container 20 . | The disclosed invention is directed to an improved storage and dispensing device, comprising a container having a plurality of dowels for storing a dispensable object and at least one opening within the container through which the object can be dispensed. The invention allows a plurality of dispensable objects to be accessed and used without removing the objects from their stored position. | 1 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention is related, in general to a computer system, in particular to booting a computer system with a set of BIOS (basic input Output System) programs.
[0003] 2. Description of the Related Art
[0004] A BIOS is a basic set of instructions which boots a computer system, and provides an interface to the underlying hardware for the operating system. A typical BIOS includes a core block and a boot block. The core block initializes a computer system and loads an operating system into a main memory. The boot block is started immediately after the power-on and reset of the system, and executes a cyclic redundancy check on the core block and allows the core block to control the system when no error is found in the core block.
[0005] The corruption of the BIOS disables the computer system for normally being booted. Therefore, a computer system often includes a plurality of BIOS programs to achieve a redundant architecture in case of an accident.
[0006] Japanese unexamined patent application No. Jp-A Heisei 11-316687 and the corresponding U.S. Pat. No. 6,167,532 disclose a computer system which includes system memory, containing BIOS instructions, having multiple bootable partitions and the ability to enable Automatic System Recovery (ASR) protection during an early phase of the boot process. Early ASR allows errors occurring during the boot process to be handled by established ASR techniques. Multiple BIOS partitions allow a user to upgrade and/or test new system routines without the potential of losing the functionality of their existing system.
[0007] Japanese unexamined patent application No. Jp-A 2000-148467 discloses a computer system which includes a BIOS ROM storing therein a pair of BIOS programs, and an address switching circuit. When an error is detected in one of the BIOS programs, the address switching circuit selects another of the BIOS programs. The selected BIOS program allows the system to be booted. Japanese unexamined patent application No. Jp-A 2000-163268 discloses another computer system similar to the aforementioned computer system.
[0008] Japanese unexamined patent application No. Jp-A 2001-92689 and the corresponding U.S. Pat. No. 6,560,726 disclose a method and system for integrated support for solving problems with personal computer systems, which comprises monitoring operating system functionality to determine if a computer system failure exists, to identify the computer system failure and to provide a solution of the computer system failure. A robust user interface, including a simple-to-use user button interface, supports single touch user input to indicate a computer system problem or question. Watchdog timers compare the time of hardware and operating system functionality, such as boot sequence operation, against predetermined time periods to determine whether or not a computer failure exists. A computer system failure is determined if a watchdog timer expires upon completion of a predetermined time period without being cleared. A hardware problem is identified on initial boot if the watchdog timer is not cleared by an operating system service routine. An operating system hang-up is determined if a watchdog timer is not cleared by an application run in association with the operating system. If a computer failure is detected, a service mode is initiated with a service mode operating system to allow in-depth analysis and problem resolution. Service mode operation is also monitored to detect problems.
[0009] Japanese unexamined patent application No. Jp-A Heisei 6-35737 discloses an automatic system recovery method to distinguish a system error resulting from an error in software from that from an electric disturbance such as noise, and to recover of the system error. When the system is reset in response to a watchdog timer expiring, a software block executed just before the reset is executed again by referring to a software history. If the system is reset again, the software block is prohibited from being executed, and the software error is recorded in an error history file. When the system is not reset during re-executing the software block, an error generation due to a disturbance is recorded in the error history file.
SUMMARY OF THE INVENTION
[0010] An object of the present invention is to provide a system and method which enables a computer system to be normally booted even if a boot block of a BIOS system is corrupted.
[0011] In an aspect of the present invention, a computer system is composed of a CPU, a timer started in response to a power-on and a reset of the computer system, a storage device storing a plurality of BIOS programs, a selector circuit selecting one of the plurality of the BIOS programs, and a system reset circuit. Each of the BIOS programs includes a boot block, and a core block which includes instructions for restarting the timer. The CPU firstly executes the BIOS program selected by the selector circuit. When the timer times out, the selector circuit selects another one of the BIOS programs. The CPU executes the newly selected BIOS program. In the meantime, the system reset circuit developing a system reset signal in response to the timer timing out for allowing the computer system to be reset.
[0012] In response to the computer system being powered on, the CPU sequentially executes the boot and core blocks of the firstly selected BIOS program. When the boot block of the firstly selected BIOS program is corrupted, the booting process does not proceed to the core block, and thus the timer is not restarted. This causes the timer to time out. Similarly, the corruption of the core block of the firstly selected BIOS program causes the timer to time out. The time out of the timer allows the selector circuit to select another BIOS program to be executed by the CPU, and causes the computer system to be reset. In response to the reset of the system, the computer system is normally booted by using the newly selected BIOS program.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] [0013]FIG. 1 is a schematic block diagram of a PC server in an embodiment;
[0014] [0014]FIG. 2 is a flowchart describing a booting process of the PC server;
[0015] [0015]FIG. 3 is a schematic block diagram of a PC server in an alternative embodiment; and
[0016] [0016]FIG. 4 is a schematic block diagram of a PC server in another alternative embodiment.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0017] Preferred embodiments of the present invention are described below in detail with reference to the attached drawings.
[0018] In one embodiment, as shown in FIG. 1, a PC server includes a CPU 1 , a memory 2 including a RAM and a ROM, a display controller 3 , an I/O controller 4 , a flash ROM 5 , a chipset 6 , a bus 7 providing connections among these elements, and a backup battery 8 .
[0019] The flash ROM 5 is a rewritable non-volatile memory storing a pair of BIOS programs 51 , and 52 , which have the same size. The BIOS program 51 includes a core block 511 and a boot block 512 , and the BIOS program 52 includes a core block 521 and a boot block 522 .
[0020] The core blocks 511 and 521 , which are identical or different versions, allow the server system to be initialized, and to boot an operation system (OS). In addition, the core blocks 511 and 512 have a function to periodically restart a watchdog timer 62 , which is described later in detail. The period of restarting the watchdog timer 62 is shorter than the timeout duration of the watchdog timer 62 .
[0021] The boot blocks 512 and 522 , which are identical or different versions, are executed immediately after the power-on and reset of the PC server to check the core blocks 511 and 512 with a CRC (cyclic redundancy checksum). The boot blocks 512 and 522 allow the core blocks 521 and 522 to start controlling the system when not finding any error in the core blocks 511 and 512 .
[0022] In this embodiment, the size of each BIOS program is 512 kByte. The flash ROM 5 provides an address space of 1 Mbytes, and the core blocks 512 is stored in the upper address space of 512 kByte, while the core blocks 522 is stored in the lower address space of 512 kByte. The flash ROM 5 is addressed by an address including address bits A 0 to A 19 . The address bit A 19 is the most significant bit of the address. Setting the address bit A 19 to logic 1 allows the BIOS program 51 to be accessed, while setting the address bit A 19 to logic 0 allows the BIOS program 51 to be accessed. The address bits A 0 to A 18 are received from the CPU 1 through the bus 7 , while the address bit A 19 is received from an output 61 of the chipset 6 .
[0023] The chipset 6 is a peripheral LSI which provides connections among the CPU 1 , the memory 2 , and a PCI (peripheral component interconnect) bus to achieve an access control, and also functions as an interface of a USB (universal serial bus).
[0024] In this embodiment, the chip set 6 includes the aforementioned watchdog timer 62 , a selector circuit 63 , and a system reset circuit 64 .
[0025] The watchdog timer 62 is a restartable hardware timer which is started in response to the power-on and reset of the PC server. The watchdog timer 62 outputs a timeout signal to the selector circuit 63 and the system reset circuit 64 if not restarted in the predetermined timeout duration T. The timeout duration T is longer than duration between the power-on (or the reset) of the PC server system and the first restart of the watchdog timer 62 caused by the core blocks 511 and 521 , when the PC server system is normally started.
[0026] The selector circuit 63 contains therein the addresses bit A 19 , and develops it on the output 61 . The selector circuit 63 inverts the addresses bit A 19 in response to receiving the timeout signal from the watchdog timer 62 . The selector circuit 63 inverts the address bit A 19 to logic 0 in response to receiving the timeout signal when the address bit A 19 is originally set to logic 1, while inverting the address bit A 19 to logic 1 in response to receiving the timeout signal when the address bit A 19 is originally set to logic 0. The selector circuit 63 may include a flipflop which inverts the output thereof in response to the input of the timeout signal.
[0027] The system reset circuit 64 develops a system reset signal in response to receiving the timeout signal from the watchdog timer 62 to allow the PC server to be reset.
[0028] The backup battery 8 supplies power to the chipset 6 to avoid the value of the address bit A 19 being erased in case of the electric power failure.
[0029] [0029]FIG. 2 is a flowchart illustrating the process of starting the PC server. The address bit A 19 , which is developed on the output 61 of the selector circuit 63 , is initially set to logic 1 to activate the BIOS program 51 . The power-on of the PC server at Step S 1 allows the watchdog timer 62 to start at Step S 2 .
[0030] In the meantime, the CPU 1 accesses the boot block 512 of the BIOS program 51 in response to the address bit A 19 being set to logic 1. The CPU 1 executes the process defined in the boot block 512 , and then executes the core block 511 .
[0031] When both of the execution of both of the boot block 512 and the core block 511 is successfully completed, the timeout of the watchdog timer 62 does not occur because the watchdog timer 62 is repeatedly restarted by the core block 511 at Step S 3 . This allows the PC server to be started by a normal procedure at Step S 4 .
[0032] On the other hand, the corruption of the boot block 512 causes the watchdog timer 62 to time out at Step S 3 , because the corrupted boot block 512 is unable to start the core block 511 , which periodically restarts the watchdog timer 62 to avoid the timeout thereof.
[0033] The corruption of the core block 511 also causes the watchdog timer 62 to time out at Step S 3 , because the corrupted core block 511 is unable to restart the watchdog timer 62 .
[0034] The timeout of the watchdog timer 62 causes the timer 62 to develop the timeout signal.
[0035] In response to receiving the timeout signal, the selector circuit 63 inverts the address bit A 19 from logic 1 to logic 0 and develops the inverted address bit A 19 on the output 61 at Step S 5 .
[0036] The system reset circuit 64 then develops the system reset signal at Step S 6 to reset the PC server in response to the timeout signal.
[0037] The same goes for the reset of the PC server except for that the address bit A 19 is set to logic 0. The reset of the PC server being reset causes the watchdog timer 62 to be started at Step S 2 . In response to the address bit A 19 being set to logic 0, the CPU 1 accesses the boot block 522 in place of the boot block 512 . The CPU 1 then executes the process defined in the boot block 522 , and then executes the core block 521 . When the execution of both of the boot block 522 and the core block 521 is successfully completed, the timeout of the watchdog timer 62 does not occur, because the watchdog timer 62 is repeatedly restarted by the core block 521 at Step S 3 . This allows the PC server to be started by a normal procedure at Step S 4 .
[0038] The corrupted core block and boot block of the BIOS program 51 and 52 may be recovered using the unbroken core block and boot block stored in the flash ROM 5 . The rewritable flash ROM 5 allows the recovery of the corrupted core block and boot block without replacing a corrupted ROM with a normal ROM.
[0039] Although the invention has been described in its preferred form with a certain degree of particularity, it is understood that the present disclosure of the preferred form has been changed in the details of construction and the combination and arrangement of parts may be resorted to without departing from the spirit and the scope of the invention as hereinafter claimed.
[0040] Especially, it should be noted that the watchdog timer 62 , the selector circuit 63 , and the system reset circuit 64 may be disposed in a BMC (baseboard management controller) 66 provided for the PC server as shown in FIG. 3. In this case, the address bit A 19 is outputted through one of the outputs of the BMC 66 . Alternatively, the watchdog timer 62 , the selector circuit 63 , and the system reset circuit 64 may be disposed in other peripheral devices.
[0041] Also, one skilled in the art would appreciate that the present invention may be applied to other computer systems, such as personal computers and workstations.
[0042] As shown in FIG. 4, the state of the selector circuit 63 , that is, the value of the address bit A 19 may be stored in a non-volatile memory 65 disposed in the selector circuit 63 . The non-volatile memory 65 may include an EEPROM.
[0043] Three or more BIOS programs may be stored in the flash ROM 5 . In this case, the BIOS programs are sequentially switched, each time the watchdog timer 62 is timed out.
[0044] The BIOS programs 51 and 52 may be stored in a mask ROM or an EEPROM in place of the flash ROM 5 . | A computer system is composed of a CPU, a timer started in response to a power-on and a reset of the computer system, a storage device storing a plurality of BIOS programs, a selector circuit selecting one of the plurality of the BIOS programs, and a system reset circuit. Each of the BIOS programs includes a boot block, and a core block which includes instructions for restarting the timer. The CPU firstly executes the BIOS program selected by the selector circuit. When the timer times out, the selector circuit selects another one of the BIOS programs. The CPU executes the newly selected BIOS program. In the meantime, the system reset circuit developing a system reset signal in response to the timer timing out for allowing the computer system to be reset. | 6 |
BACKGROUND OF THE INVENTION
The present inventon relates to an elevating cylinder device for use in positioning a barrel of a gun, particularly of a large calibre, for instance the 155 mm calibre. The elevating cylinder comprises two telescopically arranged parts, of which the first part is secured in a mounting or the like and the second part is connected with the gun barrel. Regarding the telescopic parts, the first telescopic part is made in the form of a piston unit, to the upper and under sides of which an operating medium, for instance hydraulic fluid, can be connected via first and second connection channels.
It is considered desirable for field-artillery weapons which utilize elevating cylinders to be able to make an installation which is simplified to the greatest possible extent, especially regarding the piping for transporting the operating medium between the cylinders and a source of power utilized on the gun, such as a hydraulic unit.
OBJECTS AND SUMMARY OF THE PRESENT INVENTION
The present invention is primarily concerned with these problems, and the present invention makes it possible to utilize only one medium supply pipe to the respective cylinder for the elevation and depression functions, which substantially simplifies the practical installation of piping on the gun.
A further object of the present invention is to construct an elevating cylinder of technically simple and economically advantageous components which provide efficient damping properties against upward jump or recoil movements which take place in the barrel during the firing operation. Good damping properties can then be obtained both when firing with open and with closed blocking valves. The new device is also constructed in such a way that it is possible to eliminate stresses due to temperature variations, which are known to influence the equipment when the barrel is in its clamped position.
Another object of the present invention is to provide for simple handling of the elevating and traversing functions of a gun of said kind. It is noted that the barrel can be run at the full elevating velocity towards the maximum angle of elevation, where effective, built-in damping, efficiently and gently brakes the upward movement of the barrel.
A distinguishing feature of a device formed according to the present invention is that in one of the connection channels comprising the first and second connection channels a pressure distribution valve is linked to achieve a predetermined relation between the pressure of the medium at the upper and under sides of the piston unit.
BRIEF DESCRIPTION OF THE DRAWINGS
A preferred embodiment of the present invention will be described in the following, with reference to the accompanying drawings, in which:
FIG. 1 shows a view from the side and partly in diagrammatic form of an elevating cylinder formed according to the invention;
FIG. 2 shows a diagram of the components comprising a field-artillery weapon formed according to the present invention;
FIGS. 3a-3b each show a longitudinal section of a hydraulic cylinder adaptable for use with the device formed according to FIG. 1 (FIGS. 3a and 3b should appropriately be placed together when viewing them);
FIG. 4 shows a detailed cross-sectional view of a control valve which is included in the components shown in FIG. 2; and
FIGS. 5a-5c show a unit in various sections which can be applied to the elevating cylinder formed according to FIGS. 3a and 3b and comprising a blocking valve and pressure distribution valve.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In FIG. 1, the numeral 1 designates a barrel which is elevatably supported at one end on a conventional trunnion 2. The supporting device for the barrel is arranged on an upper mounting 3 which, in turn, is transversely rotatable around a centre axis 4. The barrel 1 and upper mounting 3 are arranged on an artillery weapon, for instance a field artillery weapon, which can be of a conventional type. The barrel can have a calibre of, for example, 155 mm.
To perform the elevating function, the barrel is provided with two elevating cylinders 5, one on each side, of which only one is shown in FIG. 1. Each elevating cylinder is made with two telescopically arranged parts, of which the first telescopic part 6 has a free end rotatably secured to the upper mounting 3 in a similar way as the barrel. The telescopic first part 6 is supported on a futher supporting journal 7, so that the part 6 can be tilted in the plane of the paper in FIG. 1, while at the same time following the traversing movements of the upper mounting 3. The second telescopic part 8 is supported in a spherical support 9 of barrel 1, with the support shown in FIG. 1 being positioned at a central section of the centre part.
The displacement of the first and second telescopic parts 6 and 8 in relation to each other in the respective elevating cylinder 5 takes place with the aid of hydraulic fluid, which has the result that, in principle, the barrel will rest upon a column of hydrualic fluid in the elevating cylinder. The suspension shown for the barrel involves that there is an unbalance in the barrel for the elevation movements, i.e. the actuating force for the elevation is dependent on the angle of elevation.
The inner, or first telescopic part 6 is provided with a piston unit which will be described in more detail in the following, and the elevating cylinder 5 is moreover provided with first and second connection channels 10 and 11 for hydraulic fluid (or a corresponding medium).
At the connection with channels 10 and 11, a blocking valve 12 is arranged, with blocking valve elements 12a and 12b for the first and second connection channels, respectively, and also including a pressure distribution valve 13, consisting of a three-way hydraulic pressure control valve. The first connection channel 10 is connected via the first blocking valve element 12a to a source of operating pressure provided at point A. The second connection channel 11 is conencted to the second blocking valve element 12b and the pressure distribution valve 13, which has two control inlets 13a and 13b and two connections 13c and 13d for the passage of a medium. The control inlet 13a is then connected to the operating pressure via the connection A, and the control inlet 13b is connected via the second blocking valve element 12b and a constriction 13f so that it senses the pressure on the under side of the piston unit. The connection 13c on the pressure distribution valve is connected in parallel with the first blocking valve element 12a to the operating pressure provided at point A.
At a drain pipe 14 the pressure distribution valve is provided with a further constriction 13e. The purpose of the pressure distribution valve is to ensure that there is a predetermined relationship between the hydraulic fluid pressure on the upper and under sides of the piston units, and it is therefore arranged so that, depending on the operating pressure and the existing pressure on the under side of the piston unit, it will connect the second connection channel either to the operating pressure or to a tank 15 via the drain pipe 14. The blocking valve 12 is connected to an operating pipe via point B so that it is possible to connect or disconnect a pressure to the blocking valve for opening or closing of the blocking valve elements 12a and 12b. The blocking valve elements are intended to be opened to elevate or depress the barrel closed to provide fixed elevation or depression positions for the barrel 1, and also when the barrel is in the clamped position. The arrangement shown with blocking and distribution valves permits firing with open blocking valves, which is essential for efficient target tracking.
FIG. 2 is intended to show the complete operating equipment for the two elevating cylinders 5' and 5" necessary for elevation of the barrel 1, which are provided with identical equipment as regards the blocking valve elements 12a', 12b' and 12a" and 12b", respectively and the pressure distribution valve 13' and 13" respectively, with the constrictions 13e' and 13e" and 13f' and 13f". An operating unit 16 is also included, which is common for both the elevating and traversing functions of the gun in question. The operating unit 16 comprises a first operating valve 17 and a first control valve 18a, 18b for the elevating control. The traversing control system comprises a second operating valve 19 and a second control valve 20a, 20b. In FIG. 2, the connection points A and B positioned according to FIG. 1 are also indicated. There is also a point C indicated, which is connected to the system pressure in a hydraulic system, not shown in detail, for the field-artillery weapon in question. The connection point C, like the drain pipe 14, is connected to a tank, not shown, in the hydraulic system. The draining to the tank takes place via filters and, possibly, coolers in the system. The connection points E and F are connected to directing members, not shown, in the traversing equipment. A hand pump 21 is also indicated, by means of which the elevating and traversing can be carried out manually if the pressure in the system should be lost. Said hand pump is connected to the system pressure pipe at a point G, and to said tank via a point H.
During elevation and depression, in accordance with the above, the blocking valves 12a', 12b' and 12a", 12b", respectively, are open. Opening takes place through actuation of the operating valve 17 from the position shown in FIG. 2. During actuation, the system pressure is connected to the operating pipe of the blocking valve. Elevation or depression then takes place by means of a control lever on the control valve 18a, 18b with the operating pressure obtained from the control valve being allowed to act directly on the upper side of said piston unit. The pressure distribution valve 13', 13" achieves that the relation between the pressure of the medium on the upper and under sides of the piston unit are, for instance, 1:8 during depression and a stationary barrel. At elevation of the barrel, however, the pressure relation is varied on the upper and under sides of the piston unit with the aid of the constriction 13e', 13e". The variation is dependent on the elevating velocity. The greater the velocity, the more the pressure relation will approach 1:1. At the sudden jumping movements upwards which occur in the barrel when firing when the blocking valve elements are open, the pressure distribution valve 13 disengages the pressure distribution function by closing the drain pipe 14. Due to the unbalance in the suspension of the barrel, the speed of said jumping movement upwards is dependent on the angle of elevation at which the firing takes place. The higher the angle of elevation the greater the speed of the jumping movement upwards of the barrel. The function of the pressure distribution valve can then be chosen so that closing of the drain pipe 14 does not take place when firing at low angles of elevation, but the pressure relation assumes values closer to 1:1. The pressure distribution valve also ensures that there will never be an under-pressure on the under side of the piston unit, and thereby prevents air relese from the fluid.
The arrangement shown with pressure distribution and control valves also involves that the hydraulic fluid can be conducted to and from the upper side of the piston unit via one and the same pipe 22. Elevation takes place by filling in hydraulic fluid and depression by draining off hydraulic fluid via said pipe 22. Filling and draining takes place by means of the control valve 18a, 18b, with which also the aiming velocity is determined. The function of the control valve will be described in more detail in the following. Blocking of the blocking valves takes place by moving the operating valve back to the position shown in FIG. 2.
Traversing takes place in the corresponding way as elevating, but with the difference that the system pressure gives a counter-pressure on a so-called small area on the traversing cylinder.
As shown in FIGS. 3a and 3b, which should appropriately be viewed with their ends placed together, the first telescopic part comprises a pipe 23, at the top of which there is a tapered section 24, which starts with a pronounced shoulder 25. The pipe has a through hole, which extends through the center of the pipe in the longitudinal direction thereof. The first section 26 of the hole has a larger diameter than the second section which, in principle, extends into the tapered section 24. Pressed into the second section of the hole in the pipe 23 is an inner pipe 27, which extends through the center in the first section 26 of the hole in the pipe 23. At its lower end, the pipe 23 is secured in a supporting part 28, which is also included in the first telescopic part. Also the inner pipe 27 is inserted and sealed in the supporting part 28, which is rotatably supported on the journal 7. Arranged so that it can be fastened on the supporting part is a unit 29, shown in FIG. 5a-5c, which integrated supports the blocking valve 12a, 12b and the pressure distribution valve 13 for the elevating cylinder in question. The supporting part 28 is made in the form of a first connection hole 30 which connects the first blocking valve element 12a with the through hole 31 of the inner pipe 27 and a second connection hole 32 which connects the second blocking valve element 12b with the hole section 26 in the pipe 23.
At its other end, at about the central parts of the tapered section 24, a fixed piston part 33 is fastened, which together with a so-called floating piston part 34 is included in the above-mentioned piston unit which is allotted to the first telescopic part. The floating piston part 34 is arranged so that it can be displaced in relation to the pipe 23, between end positions which are defined by the fixed piston part 33 and the shoulder 25. Fastening of the pipe 23 in the supporting part 28, and positioning the first piston on the pipe 23 can be achieved in various ways, and in the case shown it has been done by means of threads and a nut. The fixed piston part is moreover provided with at least one constriction 35a, via which hydraulic fluid can pass from the upper side of the floating piston to the upper side of the fixed piston, or vice versa. The fixed piston is also provided with what is here called a shock valve 35b, which in order to smoothen out damping characteristics achieved by the piston unit is arranged to open the passage between the upper side of the floating piston and the upper side of the fixed piston when the pressure at the first-mentioned side exceeds the value at the last-mentioned side by a predetermined value. The shock valve comprises a spring-loaded slide, which seals against a seat in the normal case, and which is pressed away in order to permit the passage of medium in the case when the pressure on the upper side of the floating piston exceeds the pressure at the upper side of the fixed piston by the predetermined value.
Also the second telescopic part (8 in FIG. 1) comprises a pipe, which is here called the outer pipe 36, which is supported on the pipe 23 via said pistons 33 and 34, and a cylinder end 37 allotted to it and arranged at its lower end. At the upper parts of the outer pipe 36, space is provided for a compensation piston 38, which is kept pressed in the direction towards the fluid space U3 by a strong spring 39. Normally, the piston 38 is kept pressed against an end part 43 by the hydraulic pressure. The compensation piston has a recess 40, against which the compensation piston can close around the free end of the tapered section 24 when the barrel is in the depressed position (position according to FIGS. 3a, 3b) or a substantially depressed position. The compensation piston is supported in a sleeve 41, which can be screwed to the inner wall of the outer pipe at the free ends of the outer pipe. The compensation piston is then made in the form of an outwardly directed flange 42, which through coaction with a shoulder on the sleeve 41 defines one longitudinal displacement position of the compensation piston. The other longitudinal displacement position of the compensation piston is defined through the coaction of the flange 42 with an end surface of the end part 43 which is fastened in the sleeve. In the depressed position, the compensation piston 38 will be in mechanical contact with the fixed piston 33.
At its free end, the tapered section 24 is provided with a number of holes 44 located along the longitudinal direction of the section in a way which is known in itself, which through coaction with a wall section in the recess 40 in the compensation piston are included in a so-called end position damping device.
On the outer pipe 36, there is also arranged a support comprising a spherical bearing 45, contained in a bearing housing 46. A dust protecting device 47 is also applied at the bearing, to prevent dirt from entering into the support 9.
The components described above are sealed in relation to each other with seals of various kinds, and which can be of designs which are known in themselves. The sleeve 41 can be secured to the outer pipe 36 by means of threads or the like. FIGS. 3a and 3b show the completely telescoped position of the telescopic first and second parts of the elevating cylinder. At elevation, the outer pipe is actuated in the direction shown by the arrow 48.
At said piston unit with the fixed piston 33 and the floating piston 34, under the floating piston, a space U1 is formed. Between the fixed and the floating piston, a variable space U2 is obtained, and the maximum volume of the variable space is shown in FIGS. 3a and 3b. In principle, the minimum volume can be nothing at all, which would occur if the floating piston should come into contact with the under side of the fixed piston, but which last-mentioned case, however, it is here assumed will not occur. A third space U3 is formed on the upper side of the fixed piston.
The space U3 is connected with the operating pressure obtained from the control valve via inter alia the open blocking valve element 12a, the connection hole 20 and the through hole 31 in the inner pipe 27. In the depressed position of the barrel, the passage will also comprise a remaining slot between the bottom surface of the recess 40 of the compensation piston and the end surface of the tapered section 24, an eccentric hole 49 extending from the end surface of the tapered section and into the material of the tapered section in the longitudinal direction of the section, and one or several of said holes 44 for the end position damping device, which extends from the eccentric hole 49 through the material and out to the envelope surface of the tapered section. On the other hand, when the tapered section 24 is away from the recess 40, the medium in question obtains direct contact with the upper side of the first piston and via said constriction 35 with the upper side of the floating piston. The compensation piston is thus included in the end position damping device.
The space U1 is in contact with the distribution valve via the opened control valve element 12b, the hole connection 32 and the hole section 26 in the pipe 23 and a passage 50 at the inner end of the hole section 26.
Due to the unbalance in the suspension of the barrel, the pressure level of the medium present in the spaces U2 and U3 will vary in dependence on the angle of elevation of the barrel, with the pressure being approx. 25 bar at the maximum angle of elevation, and approx. 50 bar at an angle of 0°, if the medium column on which the barrel rests carries approx. 4.5 tons. On the under side of the floating piston, the pressure is kept by the pressure distribution valve at a value which for a stationary barrel and depression of the barrel is approx. 1/8 of the pressure on the upper side and for elevation movements of the barrel between 1/8 and 1/1 of the pressure on the upper side. When firing with open blocking valves, the pressure distribution function is closed entirely, possibly except at the lowest angles of elevation.
The arrangement with inter alia the fixed and the floating piston gives good damping properties for jumping movements upwards of the barrel in connection with firing with closed blocking valves. When a round is fired, the barrel is lifted upwards and the enclosed hydraulic fluid in the space U1 presses the floating piston upwards. The hydraulic fluid in the space U2 is pressed through the constriction 35 to the space U3, whereby a damping force directed against the direction of movement is obtained. The shock valve 35b sometimes enters into function also, and then limits the damping force to a certain desired adjustable level. When the kinetic energy has been consumed, the barrel falls back, and damping takes place in the opposite direction, until the floating piston has resumed its original position against the shoulder 25 in the pipe 23. The compensation piston equalizes the change in volume in the space U3, and thereby protects against under-pressure, so that there will be no air release in the fluid. The space U2 can thus be regarded as a damping volume.
When the barrel is in the clamped position, the arrangement shown also prevents stresses from arising due to variations in temperature. When the barrel is to be clamped, it is depressed with open control valves to a support utilized for the barrel. As the column of medium is connected with the drain pipe to the tank via the control valves, the pressure relief will take place with the aid of the compensation piston with the piston pressing out fluid into the tank, which involves that there will be no pressure in the system before the control and blocking valves are closed. The compensation valve is kept pressed out by its spring 39. At an increase in temperature, the remaining fluid expands. The floating piston part 34 and the compensation piston 38 take up the change in volume, and prevent any forces from being transferred from the cylinders to the clamping device, and forces from being transferred from one cylinder to the other. The clamping position is approx. 5° higher than the position shown in FIGS. 3a and 3b.
When the barrel is in its fully elevated position, the cylinder end 37 is in contact with the floating piston 34 so that in attempting to reach an elevative position beyond the maximum elevation position, it will lift the floating piston 34 from the shoulder 25. This lifting involves that the active area of the lifting force is reduced by the area of the floating piston, and has only a value as the projected area of the diameter of the tapered section which is then chosen in such a way that the barrel cannot be held with said projected area, but the barrel will strive to sink back until the floating piston again rests against its shoulder. In this way, the barrel can be run with the full elevating velocity to the fully elevated position, and an efficient braking down function is obtained, which is built into the arrangement shown.
The control valves for the elevation and traversing control are built up identically. As shown in FIG. 4, which is intended to show the control valve for the elevation, the respective control valve comprises two valve spindles 51 and 52 and an eccentric cam 53. Each valve spindle is combined with a seat valve 54 and 55, respectively, and the eccentric curve is arranged so that it can be turned by means of an operating handle 55.
The control valve also has an inlet connection C', for the system pressure, which for instance can assume a value of 110 bar, a connection A' which is connected to the connection point A in e.g. FIG. 2 and an outlet connection D', which is connected to the tank for the hydraulic system.
During actuation (lifting) of the valve spindle 52 and its seat valve 55, a connection is obtained between the connections C' and A' which is dependent on the amount of the actuation. The greater the actuation, the more fluid is fed in over to the connection A' from the connection C', whereby the aiming velocity is determined by means of the control valve. At the actuation of the valve spindle 52 and the seat valve 55, the valve spindle 51 and its seat valve 54 are closed.
At the actuation of the valve spindle 51 and the seat valve 54 by means of the eccentric cam, the connection A' is connected to the connection D', and fluid will then be conducted from A' to D', involving a depression of the barrel. During this actuation of the valve spindle 51 and the seat valve 54 the valve spindle 52 and the seat valve 55 are unactuated. In the neutral position of the eccentric cam all pipes are thus kept closed by the seat valve, so that the barrel cannot drift when there should be no aiming movement of the barrel.
The operating valve 17 (according to FIG. 2) which is included in the operating unit 16 with the control valves can consist of a hydraulic three-way two-position valve of a known type, which is spring-loaded towards one position, and electrically (via an electromagnet) actuated to its other position. The design of the blocking valve will be noted from FIG. 5a. The blocking valve elements 12a, 12b, each comprise a seat valve 56 which is actuated to its closed position by a spring 57. In FIG. 5, the connection for the operation of the blocking valve element is symbolized with B", via which connection the operating pressure for the blocking valve is conveyed to a piston unit 58 which actuates a seat valve. At the connection of the operating pressure for the blocking valve, the piston unit 58 is pressed against the force of the spring 57, and the actuation of the seat valve towards the closed position ceases, and a connection 50 and 60, respectively is connected to the connection holes 30 and 32, respectively (FIG. 3a). When the operating pressure on the unit 58 disappears, the spring 57 will again close the seat valve 56. In FIG. 5a, the distribution valve is designated with the numeral 13.
In principle, the distribution valve 13 comprises two slide valves 13g and 13h which can be displaced longitudinally, as shown in FIG. 5b. The slide valves each work against its control edge 61 and 62, respectively. The slide valves are arranged with their ends in contact with each other, the slide valve 13g then being arranged in a fixed piston lining supporting the control edge 61 which, in turn, is arranged at one end of a recess in which the slide valve 13h is applied so that it can be displaced. The slide valve 13g has a piston area which can be 1/8 of the piston area of the slide valve 13h.
When stationary and at depression of the barrel, the slide valve 13g regulates against the control edge 61 and keeps the pressure on the under side of the piston 34 (FIG. 3b) substantially constant, and so that the pressure on the under side is approx. 1/8 of the pressure on the upper side. During depression of the barrel, fluid is fed from the connection A to the connection hole 32 (the connection channel 11) over said control edge 61. At the same time, hydraulic fluid on the upper side of the piston unit 33, 34 is returned to the tank.
During elevation of the barrel, fluid is fed from the inlet A to the connection hole 30 (=connection channel 10) to the upper side of the piston unit 33, 34, and at the same time fluid is drained from the under side of the piston 34 to the drain pipe 14 (FIG. 5c), which takes place via the control edge 62 and the constriction 13e (FIG. 5c). The constriction 13e causes a velocity dependent added force to be obtained via a channel 13i on the side of the slide valve 13h which coacts with the slide valve 13g. The added force strives to close the valve against the drain pipe 14, whereby the pressure relation is changed in dependence on the elevating velocity, and at the highest elevating velocities approaches 1:1.
When firing, jumping movements upwards are obtained in the barrel, which particularly at high angles of elevation will be of a magnitude that involves that said added force assumes values which cause closing of the drain pipe 14. The piston unit 33, 34, can in this way carry out the damping function described above, even if firing takes place with open blocking valves.
The slide valves 13g and 13h work with long overlapping sections 13k and 13l, respectively, which prevent an undesirable flow of hydraulic fluid in the closing positions of the valves.
The length of stroke of the telescopic units is of the magnitude of 0.8 m.
The invention is not limited to the embodiment shown above as an example, but can be subject to modifications within the scope of the following claims. | Apparatus for supporting and elevating a gun barrel, wherein a pair of telescoping cyclinders are attached to the barrel and frame of the gun, respectively. A piston assembly positioned between the cylinders supports the unbalanced weight of the barrel against a fluid medium with a control valve varying the resulting pressure ratio during elevation of the barrel. | 5 |
This application is a continuation of application Ser. No. 08/052,228, filed Apr. 22, 1993, which is a continuation of Ser. No. 860,818, filed Mar. 31, 1992.
FIELD OF THE INVENTION
The present invention relates to the field of radiographic analysis of the human body and, in particular, to a method of measuring and displaying tomographic views of compact structures embedded in the human body.
BACKGROUND OF THE INVENTION
In a computed tomography system ("CT system"), an x-ray source is collimated to form a fan beam with a defined fan beam angle and fan beam width. The fan beam is oriented to lie within the x-y plane of a Cartesian coordinate system, termed the "imaging plane", and to be transmitted through an imaged object to an x-ray detector array oriented within the imaging plane.
The detector array is comprised of detector elements which each measure the intensity of transmitted radiation along a ray projected from the x-ray source to that particular detector element. The detector elements can be organized along an arc, matching the fan beam angle each to intercept x-rays from the x-ray source along a different ray of the fan beam.
The intensity of the transmitted radiation received by each detector element in the detector array is dependent on the attenuation of the x-ray beam along a ray by the imaged object. Each detector element α produces an intensity signal I.sub.α dependent on the intensity of transmitted radiation striking that detector element α.
The x-ray source and detector array may be rotated on a gantry within the imaging plane so that the fan beam intercepts the imaged object at different angles. At each angle, a projection is acquired comprised of the intensity signals from each of the detector elements α. The projections at each of these different angles together form a tomographic projection set.
Normally a projection set will be taken over 360° of gantry rotation, however, it is known to obtain a projection set with as little as 180° plus half subtended fan beam angle, by making use of the fact that the attenuation of an x-ray by the imaged object is relatively unchanged when the x-rays travel in opposite directions along a single ray. An attempt to reconstruct an image with less than a projection set will normally lead to image artifacts caused by the missing data.
A gantry that may support the x-ray tube and detector array over rotations of more than 180° is costly to construct and can be bulky.
The acquired tomographic projection set is typically stored in numerical form for computer processing to "reconstruct" a slice image according reconstruction algorithms known in the art. The reconstructed slice images may be displayed on a conventional CRT tube or may be converted to a film record by means of a computer controlled camera.
The volume subtended by the fan beam, as intercepted by the detector elements during rotation of the gantry, defines the field-of-view of the CT system.
The amount of data required to reconstruct a CT image is a function of the CT system's field-of-view, the larger the field-of-view, the more data that must be collected and processed by the CT system and thus the longer the time required before an image can be reconstructed. The acquisition of additional data in each projection also increases the cost and number of the components of the CT system.
Therefore, for imaging compact structures within the body, it would be desirable to limit the field-of-view to an angle commensurate with the cross-sectional area of that compact structure. Such a reduction in field-of-view, accompanied by a reduction in the size of the fan beam, would reduce the total dose of x-rays received by the patient. In a CT machine constructed for only imaging compact structures, a reduced field-of-view would reduce the cost of the machine and provide increased image reconstruction speed as a result of the reduced amount of data required to be processed. Also, as is known in the art, smaller field of view images may be reconstructed faithfully using fewer projection angles, thereby further reducing the reconstruction times. The reduced cost of such a machine would result primarily from the reduced number of detectors and associated data handling circuitry required, and from the less powerful image reconstruction processor required to handle the amount of reduced data. Cost savings from a resulting simplified mechanical construction might also be achieved.
Unfortunately, for a CT system to accurately reconstruct images of a compact structure within an attenuating body, it is ordinarily necessary that the entire body containing the compact structure be within the CT system's field-of-view. Even when the only structure of interest is centrally located and its attenuation properties are very different than those of the rest of the section, such as the spine within an abdominal section, conventional CT methods require that substantially the entire object be within the field of view. If the body containing the compact structure extends beyond the field-of-view of the CT system, then projections at some gantry angles will include attenuation effects by volume elements of the body not present in projections at other gantry angles. For the present discussion, these volume elements present in only some projections are termed "external volumes".
In the reconstruction process, the attenuation caused by external volumes is erroneously assigned to other volume elements in the reconstructed image. This erroneous assignment produces artifacts, manifested as shading or cupping, and sometimes as streaks, in the reconstructed tomographic image and are termed "truncation artifacts".
Selective material imaging by use of x-ray transmission measurements at multiple energies is known. However, when used in a CT mode, prior methods acquired data for the entire object.
SUMMARY OF THE INVENTION
The present invention provides a method for reducing the effect of external volumes on the reconstructed image and thus allowing the construction of a reduced field-of-view CT machine, in cases where the goal is to form an image of a compact structure whose attenuation properties differ from those of the rest of the section. The different energy dependence of the attenuation of the compact structure and the body is exploited to produce a projection set reflecting only the compact structure. This projection set is created from a combination of two projection sets taken at different x-ray energies.
Specifically, radiation having first and second energies is projected through the compact structure and portions of the body over the field-of-view and a first and second projection set at the first and second energies is acquired. The first and second projection sets are then combined to produce a third projection set dependent substantially on only the attenuation of the compact structure. This third projection set is reconstructed into an image of the compact structure.
The present invention relies on the realization that external volumes do not contribute to the values in this third projection set, and therefore their absence do not detract from the accuracy of the final image forward from the third projection.
It is thus one object of the invention to reduce the truncation artifacts affecting a reduced field-of-view CT machine in applications where the compact structure to be imaged is embedded in or attached to a second structure outside of the field-of-view of the CT machine, and has differential attenuation properties.
It is another object of the invention to reduce the width of the radiation beam of a conventional CT machine to approximately match the width of a compact structure of interest, thus reducing total patient exposure, without creating unacceptable truncation artifacts.
In one embodiment, the present invention employs a C-arm providing less than 180° of rotation of the x-ray source and detector rather than a conventional gantry. Use of dual energy measurements to eliminate the effect of the portions of the body around the compact structure reduces the image artifacts from these portions thus reducing image artifacts resulting from the acquisition of less than a complete projection set on the C-arm.
Thus it is another object of the invention to permit use of the more versatile and less cumbersome C-arm architecture on a tomographic system.
The use of dual energy measurements permits the elimination of spectral shift artifacts as is taught in U.S. Pat. No. 4,029,963 to Alvarez hereby incorporated by reference. It is thus another object of the invention to further reduce spectral shift artifacts which may be exacerbated by the use of a small field-of-view system or limited projection sets.
Other objects and advantages besides those discussed above shall be apparent to those experienced in the art from the description of a preferred embodiment of the invention which follows. In the description, reference is made to the accompanying drawings, which form a part hereof, and which illustrate one example of the invention. Such example, however, is not exhaustive of the various alternative forms of the invention, and therefore reference is made to the claims which follow the description for determining the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view in elevation of the gantry of a reduced field-of-view CT machine showing "external volumes" within a body surrounding a contrasting compact structure of interest, said external volumes not within the field-of-view of the CT machine but nevertheless attenuating the radiation beam at some gantry angles;
FIG. 2 is a block diagram of a first embodiment of the reduced field-of-view CT system of FIG. 1 useful for practicing the present invention;
FIG. 3 is a block diagram of a second embodiment of a reduced field-of-view CT system of FIG. 1 useful for practicing the present invention;
FIG. 4 is a block diagram of a third embodiment of a reduced field-of-view CT system of FIG. 1 useful for practicing the present invention; and
FIG. 5 is a perspective view of a C-arm tomographic system useful for practicing the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
I. Selective Imaging with Two Energies
Referring to FIG. 1, a radiation source 10 is mounted on the rim of a generally circular gantry 12 to generate a diametrically oriented fan beam 14 of radiation with a narrow fan angle φ. The gantry 12 is operable to rotate through angles θ about a center of the gantry 16 within an image plane 18 with the fan beam 14 parallel to the image plane. A patient 20 is positioned at the center of the gantry 16 so that a cempact structure of interest 22, such as the spine, is within the field-of-view 24 defined by the volume irradiated by the fan beam 14 at all of a plurality of gantry angles.
The fan beam 14 is received by a detector array 26 having a plurality of detector elements 28 positioned on the gantry 12 opposite to the radiation source 10 with respect to patient 20 and the gantry center 16. Each detector element 28, distinguished by index α, measures the intensity I.sub.α of the fan beam 14 attenuated by the patient 20 along a ray 30 of the fan beam 14 at angle φ.sub.α extending from the radiation source 10 to the center of that detector element 28. The collection of intensity measurements I.sub.α, for all detector elements 28 at a gantry angle θ forms a projection and the collection of projections for all gantry angles θ forms a projection set.
The fan angle φ is such as to subtend the compact structure 22 at the plurality of gantry angles θ but is less than that required to subtend the entire cross section of the patient 20 in the image plane 18. This limited extent of the fan beam 14 significantly reduces the complexity and expense of the detector array 26 and the succeeding processing electronics (not shown in FIG. 1). The limited fan angle φ of the fan beam 14 also causes certain volume elements 32 ("external volumes") of the patient 20 to contribute to a projection obtained at a first gantry angle θ=θ 1 but not to contribute to a projection at a second gantry angle θ=θ 2 . As mentioned, these external volumes 32 that are present in only some of the projections of a tomographic projection set create artifacts in the reconstructed image. Generally, all volumes outside of the field-of view 24 are external volumes 32.
The acquisition of two projections at two different energies of radiation from radiation source 10 can be used to eliminate the contribution of these external volumes 32 to the projections, provided that the characteristic attenuation function of the material of the external volume 32 are suitably different from those of the material of the compact structure 22.
Monoenergetic Imaging
If two projections are obtained representing the attenuation of the fan beam 14 along rays 30 by the patient 20 for two radiations energies, these projections may be used to distinguish between the attenuation caused by each of two different basis materials: one material of the external volumes 32 and one material of the compact structure 22. Thus the attenuation of the material of the external volumes 32 and of the compact structure 22 may be determined and the effect of the former eliminated from the projections. The distinction between radiation energy or frequency, and intensity or flux is noted.
The intensity measurement I.sub.α1 along a ray α of a first high energy of fan beam 14 radiation will be:
.sub.α1 =I.sub.01 e.sup.- (.sup.μ e1.sup.M e.sup.+μ c1.sup.M.sub.c) (1)
where I 01 is the intensity of the fan beam 14 of radiation absent the intervening patient 20; μ e1 and μ c1 are the known values of the mass attenuation coefficient (cm 2 /gm) of the material of external volume 32 and of compact structure 22 respectively at this first radiation energy; and M e and M c are the integrated mass (gm/cm 2 ) of external volume 32 and of compact structure 22, respectively.
This equation may be simplified as follows: ##EQU1##
The values of μ e1 and μ c1 of equation (1) are dependent on the energy of the radiation of the fan beam 14 and on the chemical compositions of the materials 32 and 22.
As is well known in the art, the values of μ e1 and μ c1 may be measured, or computed, given the chemical composition of the materials.
A second intensity measurement I.sub.α2 along the same ray 30, at a second radiation energy, will be given by the following expression: ##EQU2##
where μ e2 and μ c2 are different from μ e1 and μ c1 , by virtue of the different photon energy, and I 02 is the incident intensity. Again, μ e2 and μ c2 may be measured or computed.
Equations 2 and 3 are two independent equations with two unknowns, M e and M c , and may be solved simultaneously to provide values for M e and M c . For example, ##EQU3##
This, in turn, results from the different energies of the two beams and from the different chemical compositions of the two materials (fundamentally, different relative contributions of photoelectric absorption and Compton scattering for the two materials).
With knowledge of M e and M c , the contribution of the external volume 32 may be eliminated by substituting for the intensity measurement I.sub.α1 the value I 01 e - μ cl M c, or more simply, by using the calculated value M c directly in the reconstruction algorithms as is understood in the art. The creation and measurement of two monoenergetic radiation beams will be described further below.
Polyenergetic Imaging
Faster imaging requires a stronger radiation source 10, which also often entails an increase in the width of the energy spectrum of the radiation source 10 at each energy E. For such broadband radiation, equations (2) and (3) above, become more complex requiring an integration over the spectrum of the radiation source 10 as follows:
I.sub.α =∫I.sub.0 (E)e.sup.-{M e.sup.μ e(E).sup.+M c.sup.μ c(E)}de (5)
Such equations do not reduce to a linear function of M e and M c after the logarithm, and hence more complex nonlinear techniques must be adopted to evaluate M e and M c .
One such technique, termed the closed form fit approximates the value of M c as a polynomial function of the log measurements along ray α at a high and low energy, for example:
M.sub.c =k.sub.1 L.sub.1 +k.sub.2 L.sub.2 +k.sub.3 L.sub.1.sup.2 +k.sub.4 L.sub.2.sup.2 +k.sub.5 L.sub.1 L.sub.2 (6)
M e can similarly be computed.
It will be recognized that polynomials of different orders may be adopted instead. The coefficients of the polynomial, k 1 through k 5 , are determined empirically by measuring a number of different, calibrated, superimposed thicknesses of the two materials to be imaged. Alternatively, it is known that the total measured polyenergetic attenuation can be treated as if the attenuation had been caused by two dissimilar "basis" materials. Aluminum and Lucite™ have been used as basis materials. The computed basis material composition is then used to compute M e and M c . The advantage of this approach is that it is easier to build calibration objects from aluminum and Lucite™ than, for example, bone and soft tissue. The decomposition of an arbitrary material into two basis materials and further details on selective material imaging are described in the article "Generalized Image Combinations in Dual KVP Digital Radiography", by Lehmann et al. Med. Phys. 8(5), Sept/Oct 1981.
The determination of the coefficients of equation (6) is performed with a radiation source having the same spectral envelopes as the radiation source 10 used with the CT apparatus. The coefficients are determined using a Least Squares fit to the empirical measurements developed with the known thicknesses of the models.
As indicated by the above discussion, the ability to distinguish between two materials 32 and 22, and thus the ability to discount the effect of one such material (32) requires a differential relative attenuation by the materials caused by photoelectric and the Compton effects. This requirement will be met by materials having substantially different average atomic numbers and is enhanced by increased difference in the two energies.
It is possible that the external volumes 32 of the patient 20 will include more than one type of material. An examination of the equations (3) and (4), however, reveals that the above described method will not unambiguously identify the thicknesses of a material in the presence of more than two material types within the patient 20. As a result, the above described method works best when the material of the compact structure 22 and the materials of the partial volumes 32 have sufficiently different attenuation functions so that the variations among tissue types of the external volumes 32 are small by comparison. Examples are where the compact structure 22 is bone and the partial volumes 32 are muscle, water or fat; or where the compact structure contains iodinated contrast agent and the external volumes 32 do not. These limitations are fundamental to dual energy selective material imaging and are not unique to the present use. In any case, errors resulting from the simplifying assumption of their being only two materials in body 20, one for the compact structure 22 and one for the external volumes 32 are low enough to permit the above method to be used for the intended reduction of image artifacts.
II. Dual Energy Reduced Field-of-View CT Apparatus
Referring now to FIGS. 1 and 2, in a first embodiment CT gantry 12 holds a radioisotope 34 which produces the fan beam of radiation 14 directed toward the patient 20. The radioisotope 34 is preferably a radioactive isotope such as GD 153 , which when filtered by filter 36 prior to the fan beam 14 intercepting the patient 20, produces a fan beam 14 composed of radiation in one of two distinct and essentially monoenergetic bands. After passing through the patient 20, this radiation is received by a detector array 26(a) comprised of a number of detector elements 28 which together receive and detect radiation along each ray 30 of the fan beam 14 to produce separate signals I.sub.α1 and I.sub.α2 for each detector element α and for each energy of radiation.
The detector 26(a) is a scintillating crystal type detector, coupled to a photomultiplier tube, or alternatively a proportional counter using xenon or other high atomic weight gas such as is well understood in the art. Alternatively, the detector array may be a combination photo detector and two scintillating materials atuned to different energy levels. With either such detector 26(a), the energy level of the received radiation of the fan beam 14 is measured by a pulse height analyzer 38 which measures the energy deposited by each quantum of radiation, either pulses of light detected by the photodetector in the crystal-type detector 26(a) or pulses of charge produced by the proportional counter 26(a). The pulse height analyzer 38 characterizes each pulse, by its height, as either high or low energy. The counts of high and low energy pulses for a fixed period of time become the measures I.sub.α1 and I.sub.α2, respectively. The data for each detector element 28(a) is processed by selective material computation circuit 40 which performs the calculations described above (e.g. equation 4), to produce a projection set containing attenuation information for the compact structure 22 only.
The control system of a CT imaging system suitable for use with the present invention has gantry motor controller 42 which controls the rotational speed and position of the gantry 12 and provides information to computer 44 regarding gantry position, and image reconstructor 46 which receives corrected attenuation data from the selective material computation circuit 40 and performs high speed image reconstruction according to methods known in the art. Image reconstructor 40 is typically an array processor in a large field-of-view CT machine, however in the present invention, with a reduced field-of-view, the image reconstruction may be performed acceptably by routines running in a general purpose computer.
Electric communication between the rotating gantry 12 and the selective material computations circuit 40 is via retractable cabling (not shown) which is paid out for a limited number of gantry rotations and then returned to take up spools for the same number of gantry rotations in the other direction.
The patient 20 rests on a table 48 which is radiotranslucent so as to minimize interference with the imaging process. Table 48 is controlled so that its upper surface translates across the image plane 18 and may be raised and lowered to position the compact structure 32 within the field-of-view 24 of the fan beam 14. The speed and position of table 48 with respect to the image plane 18 and field-of-view 24, is communicated to and controlled by computer 44 by means of table motor controller 50. The computer 44 receives commands and scanning parameters via operator console 52 which is generally a CRT display and keyboard which allows the user to enter parameters for the scan and to display the reconstructed image and other information from the computer 44.
A mass storage device 54 provides a means for storing operating programs for the CT imaging system, as well as image data for future reference by the user.
Referring to FIGS. 1 and 3, in a second embodiment of the invention, an x-ray tube 56 is held on gantry 12 as the radiation source 10 in place of the radioisotope 34 of FIG. 2. The dual energies of radiation are produced by switching the operating voltage of the x-ray tube 56 as is well understood in the art. Synchronously with the switching of the voltage on the x-ray tube 56, one of two filter materials of filter wheel 58 is rotated into the path of the fan beam 14 on a rotating filter wheel, prior to the beam intercepting the patient 20. The filter materials serve to limit the bandwidth of the polyenergetic radiation from the x-ray tube 56 for each voltage. The filter wheel 58 and the x-ray tube are controlled by x-ray control 62.
A single integrating type detector 26(b) employing either a scintillating crystal type detector or a gaseous ionization type detector coupled to an electrical integrator is used to produce the intensity signal, and the integrated signal for each energy level is sampled synchronously with the switching of the bias voltage of the x-ray tube 56 and the rotation of the filter wheel 58, by data acquisition system 60 to produce the two intensity measurements I.sub.α1 and I.sub.α2 used by the selective material computation circuit 40 employing the polyenergetic corrections technique previously described (e.g. Equation 6).
In all other respects, the CT system in this embodiment is the same as that described for the first embodiment.
Preferably, two projection sets are acquired, one at high x-ray energy, and one at low x-ray energy, at each gantry angle θ before the gantry 12 is moved to the next gantry angle θ in an "interleaved" manner so as to minimize problems due to possible movement of the patient 20. It will be apparent to one of ordinary skill in the art, however, that each projection set may be acquired in separate cycles of gantry rotation, the advantage to this latter method being that the x-ray tube voltage and the filter wheel 58 need not be switched back and forth as frequently or as fast.
Referring to FIGS. 1 and 4, in a third embodiment, the radiation source 10 is an unmodulated x-ray tube 56 producing a polyenergetic fan beam 14 as controlled by x-ray control 62. This fan beam 14 is filtered by stationary filter 64 to concentrate the spectral energies of the x-ray radiation into a high and low spectral lobe. Stationary filter 64 is constructed of a material exhibiting absorption predominantly in frequencies or energy between the two spectral lobes. A detector 26(c) is comprised of a primary and secondary integrating type detector 66 and 68 arranged so that the fan beam 14, after passing through the patient 20, passes first through primary detector 66 and then after exiting the primary detector, passes through the secondary detector 68. Each detector 66 and 68 is a gaseous ionization detector filled with an appropriate high atomic number gas such as xenon or a scintillation detector. Relatively lower energy x-ray photons will give up most of their energy in the primary detector 66 and be recorded as the low energy signal I.sub.α1 for that ray 30 in fan beam 14. These lower energy x-ray have a high probability of interacting in the short distance occupied by the primary detector 66 because the attenuation of the detector is higher at the lower energies. The higher energy photons will give up proportionally more of their energy in the secondary detector 68 and thereby produce the higher energy signal I.sub.α2. These two signals are collected by a data acquisition system 70 and used to produce selective material projections by circuit 40 using the polychromatic techniques described above, and reconstructed into an image as before.
In all other respects the CT system of the third embodiment is the same as that described for the first embodiment.
Typically projection data will be acquired over 360° of gantry rotation each projection including information on the attenuation of the radiation source for radiation at both of the radiation energies. As is known in the art, however, images may be reconstructed from a "half scan" of projection data acquired over less than 360° of gantry rotation provided at least a minimum gantry rotation of 180° plus the fan beam angle is obtained. Image reconstruction using less than 360° of projection data can further reduce the data required to be processed by the image reconstructor 46. The weighting and reconstruction of images from a half scan data set are discussed in detail in "Optimal Short Scan Convolution Reconstruction for Fanbeam CT", Dennis L. Parker, Medical Physics 9(2) March/April 1982.
Generally, image reconstruction using less than a half scan of projection data will introduce artifacts into the reconstructed image. The severity of these artifacts depends on the amount of missing data and the degree to which the missing data may be estimated or approximated. For certain compact structures where surrounding tissue can be removed by dual energy techniques, it is believed that the small amounts of missing projection data can be tolerated and that less than a half scan of data may be employed, both permitting the use of the more versatile C-arm architecture and further reducing the amount of data needed in the reconstruction also reduces the dose that the patient receives.
Referring now to FIG. 5, a C-arm radiographic system 110 of a fourth embodiment constructed according to a C-arm architecture, includes a table 112, for supporting a patient 114 in a supine position along a longitudinal or z-axis 116 of a Cartesian coordinate system.
Support pillars 120 hold the longitudinal end of the table 112 and are attached at their bottom ends to a bed 128 supporting the radiographic system 110. The support pillars may telescope to move the table 112 up and down in the y-axis of the Cartesian coordinate system.
The bed 128 includes two longitudinal rails 132 which form a track for supporting a transversely extending gantry pallet 134, and which allow the gantry pallet 134 to be positioned longitudinally along substantially the entire length of the radiographic system 110 along the z-axis 116.
The gantry pallet 134 includes transverse rails 133 carried by rollers (not visible) fitting within the rails 132. Riding on the rails 133 of the gantry pallet 134 is a C-arm collar 138 which may be moved in the x-axis 115 of the Cartesian coordinate system.
Collar 138 is generally arcuate to enclose and slideably hold a C-arm 140 such that the ends of the C-arm may rotate about a center 142 as the body of the C-arm 140 slides through the collar 138. Motion of the C-arm 140 moves the radiation source 144 and detector array 145 about the center 142 by an angle θ. The geometry of the C-arm 140 is such that the angle θ is less than 180° by the width of the collar 138 measured along the C-arm 140.
A radiation source 144 and detector array 145 may be any of those previously described with respect to the first through third embodiments and are mounted so as to produce a fan beam aligned with the plane of rotation of the C-arm 140 and adjustable to subtend a compact structure such as a vertebrae within the patient 114 without significantly illuminating the surrounding tissue.
A radiographic system suitable for use with the present invention is described in further detail in U.S. application 07/976,797 entitled: Patient Positioning Apparatus for Bone Scanning, assigned to the assignee of the present application and hereby incorporated by reference.
The limitation of the rotation of the C-arm 140 within the collar 138 prevents a half scan of projections from being obtained. As is known in the art, each projection provides data along a line of diameter in a circle of Fourier data used to reconstruct a tomographic image. The missing data results in two pie-shaped opposed sectors of missing Fourier data. This data may be estimated by extrapolating from the data that is obtained. A number of techniques are known in the art. See for example U.S. Pat. No. 4,506,327 to Tam hereby incorporated by reference.
Specifically, for imaging the spine first, projections over the full range of the C-arm 140 are acquired at each of the dual energies. The information of the dual energies is used, as has been described, to create a new projection set including only attenuation data caused by bone and thus primarily data of the vertebrae being imaged. The composition of the soft tissue, used to cancel out the soft tissue image, is determined from rays of one or more projections within the limited angle fan beam know to pass only through soft tissue.
The attenuation data attributable only to bone is then reconstructed using half scan reconstruction techniques with the missing data estimated. Preliminary data indicates that with the removal of the soft tissue, and thus the elimination of artifacts caused by the missing soft tissue, acceptable tomographic images of vertebrae can be obtained with a range of projections obtainable by a C-arm architecture.
It will occur to those who practice the art that many modifications may be made without departing from the spirit and scope of the invention. For example, other similar combinations of the detectors and radiation sources, three of which are described above, may be used to create the dual energy signals I.sub.α1 and I.sub.α2. The mechanical structure of the CT apparatus may be based on other well known geometries such as the "translate/rotate" configuration of CT scanner where the radiation source 10 and a detector 26 are translated together across the patient. Also, other energy dependent attenuation effects, for example the k-edge absorption of certain materials such as iodine, may be employed. In order to apprise the public of the various embodiments that may fall within the scope of the invention, the following claims are made. | A CT apparatus for scanning compact structures associated with a larger body uses radiation source producing a reduced field-of-view to simplify construction and reduce exposure of the larger body. Truncation artifacts in the reconstructed image caused by volume elements in the larger body imaged by the radiation beam only for projections at some angles, are reduced by acquiring two projections at two different energies and combining those projections to compensate for the attenuation of the radiation by the volume elements of the larger body. | 7 |
CONTINUATION APPLICATION DATA
The present application is a continuation-in-part of prior filed U.S. application No. 08/187,118, filed 25 Jan. 1994, now U.S. Pat. No. 5,399,891 which is a continuation of U.S. application No. 07/823,892, filed 22 Jan. 1992, now U.S. Pat. No. 5,341,468 invented by Yiu, et al.
RELATED APPLICATION DATA
The present application is related to co-pending application entitled FLASH EPROM INTEGRATED CIRCUIT ARCHITECTURE, filed on the same day as the present application, invented by Yiu, et al., and owned by the same Assignee as the present application now and at the time of invention.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to flash EPROM memory technology, and more particularly to unique cell structure having extended floating gates to improve the coupling ratio between the control gate, floating gate, and source or drain of the transistor cell.
2. Description of Related Art
Flash EPROMs are a growing class of non-volatile storage integrated circuits. These flash EPROMs have the capability of electrically erasing, programming, and reading a memory cell in the chip. The memory cell in a flash EPROM is formed using so-called floating gate transistors, in which the data is stored in a cell by charging or discharging the floating gate. The floating gate is a conductive material, typically made of polysilicon, which is insulated from the channel of the transistor by a thin layer of oxide, or other insulating material, and insulated from the control gate or word line of the transistor by a second layer of insulating material.
Data is stored in the memory cell by charging or discharging the floating gate. The floating gate is charged through a Fowler-Nordheim tunneling mechanism by establishing a large, positive voltage between the control gate and source or drain. Alternatively, an avalanche mechanism may be used by applying potentials to induce high energy electrons in the channel of the cell which are injected across the insulator to the floating gate. The voltage on the control gate is divided by the so-called coupling ratio of the cell, resulting in a first voltage between the control gate and floating gate, and a second voltage between the floating gate and the source or drain. With a 50% coupling ratio, half of the voltage applied to the control gate appears across the oxide between the floating gate and the source or drain. This voltage between the floating gate and the source or drain causes electrons to tunnel or be injected into the floating gate through the thin insulator. When the floating gate is charged, the threshold voltage for causing the memory cell to conduct is increased above the voltage applied to the word line during a read operation. Thus, when a charged cell is addressed during a read operation, the cell does not conduct. The non-conducting state of the cell can be interpreted as a binary 1 or a zero, depending on the polarity of the sensing circuit.
The floating gate is discharged to establish the opposite memory state. This function is typically carried out by F-N tunneling between the floating gate and the source or drain of the transistor, or between the floating gate and the substrate. For instance, the floating gate may be discharged through the source by establishing a large, positive voltage from the source to the gate, while the drain is left at a floating potential.
The high voltages used to charge and discharge a floating gate place significant design restrictions on flash memory devices, particularly as the cell dimensions and process specifications are reduced in size. Thus, the coupling ratio for the memory cells becomes a critical design parameter.
One way of increasing the coupling ratio, is to increase the surface area of the floating gate between the control gate and the floating gate. This can be accomplished by extending the floating gate over the source or drain regions, such as described in Bergemont, et al., U.S. Pat. No. 5,012,446.
One approach to extending the floating gate is described in Kume, et al., "A 1.28 μm 2 Contactless Memory Cell Technology for a 3 V-only 64 Mbit EEPROM", IEDM 92, pp. 991-993; Hisamune, et al., "A High Capacitive-Coupling Ratio (HiCR) Cell for 3 V-only 64 Mbit and Future Flash Memories", IEDM 93, pp. 19-22.
All of these prior art designs for extending the floating are relatively complicated process technologies.
Accordingly, an improved process for extending the floating gate to increase the coupling ratio of flash EPROM, and a circuit for utilizing such structure, is desirable.
SUMMARY OF THE INVENTION
The present invention provides novel contactless, flash EPROM cell and array designs, and methods for fabricating the same, which result in dense, segmentable flash EPROM chip. The flash EPROM cell is based on a unique drain-source-drain configuration, in which a single source diffusion is shared by two columns of transistors. Also, a new memory circuit architecture suited for the flash EPROM cells of the present invention is possible.
According to one aspect of the present invention, a flash EPROM transistor array is provided which is manufactured in a substrate having a first conductivity type. A drain diffusion region of a second conductivity type is formed in the substrate and elongated in a first direction having a drain width transverse to the first direction. A source diffusion region of a second conductivity type is placed in the substrate, elongated in the first direction, and spaced away from the drain diffusion region to provide a channel region between the source and drain diffusion regions. An insulating layer is placed over the channel region and over the source and drain diffusion regions. A plurality of floating gate electrodes are formed overlying the first insulating layer over the channel region. A second insulating layer is placed over the floating gate electrodes, and a plurality of control gate electrodes are formed over the second insulating layer, elongated in a second direction which intersects the source and drain diffusion regions over the respective floating gate electrodes. This establishes a plurality of flash EPROM transistors in a column across the channel region.
According to the present invention, the floating gate electrodes comprise a first conductive layer deposited in a first deposition process having a first major surface adjacent the first insulating layer with a channel surface area over the channel region. A second major surface of the floating gate electrode opposite the first major surface has a surface area substantially equal to the channel surface area. The sides of the floating gate electrode between the first and second major surfaces are used to define the channel length during a diffusion process which forms the source and drain diffusion regions. A conductive spacer is deposited after the diffusion process, contacting the first conductive layer on at least one of the sides to provide in combination with the first conductive layer a floating gate electrode having a control surface area under the control electrode substantially greater than the channel surface area.
The conductive spacer is preferably placed on both sides of the floating gate electrode to extend the floating gate out over both the source and drain diffusion regions. These conductive spacers may be substantially symmetrical, which provides for easy scaling of the process to smaller and smaller dimensions.
Further, a process for implementing a flash array in the drain-source-drain configuration includes the floating gate electrodes consist of a first polysilicon layer over the channel region, a second polysilicon layer contacting the first polysilicon layer. In one aspect of the invention, the floating gate for a cell on one side is elongated in a direction out over the first drain diffusion region in an amount substantially greater than one-half the drain width. The cell on the opposite side of the drain-source-drain configuration, has a floating gate which extends over the second drain diffusion region in the opposite direction in a symmetrical manner. This allows a designer to take advantage of the space consumed by isolation regions to improve the coupling ratio.
The present invention can also be characterized as a unique method for fabricating flash EPROM transistors on a substrate which includes the following steps:
A method for fabricating a plurality of flash EPROM transistors on a substrate, comprising:
forming a floating gate insulating layer over at least a portion of the substrate;
defining a plurality of strips of polysilicon in a first polysilicon deposition over the floating gate insulating layer;
exposing the substrate to dopants so that the plurality of strips act as a mask and a plurality of doped regions in the substrate are formed between the plurality of strips of conductive material;
annealing the substrate to drive in the dopants in the doped regions to establish buried diffusion regions aligned with the strips of polysilicon;
forming a thicker insulator with an insulating material over the buried diffusion regions
exposing the plurality of strips of polysilicon;
depositing a second polysilicon deposition over and in contact with the plurality of strips;
etching the second polysilicon deposition for a predetermined time to form self-aligned conductive spacer lines overlying the thicker insulator over the buried diffusion regions, each conductive spacer line contacting only one of the plurality of strips;
forming a control gate insulator over the plurality of strips and the conductive spacer lines;
depositing a third polysilicon deposition over the control gate insulator; and
etching the third deposition to define control gate conductors, and the conductive spacers and the plurality of conductive strips to define floating gates.
Thus, a unique flash EPROM cell structure and process for manufacturing the same is provided capable of achieving high packing densities. The structure has a high coupling ratio, so that lower voltages may be utilized in programming and erasing the cells. Also, the design allows for a number of other advantages which can be seen upon review of the figures, the detailed description and the claims which follow.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is a schematic diagram of a flash EPROM integrated circuit module according to the present invention.
FIG. 2 is a schematic diagram of a drain-source-drain configured, virtual ground, flash EPROM array according to one embodiment of the present invention.
FIG. 3 is a schematic diagram of an alternative embodiment of the present invention with two columns of flash EPROM cells sharing a single metal bit line.
FIG. 4 is a schematic block diagram of a segmentable flash EPROM array with redundant rows for correction of failed rows in the main array.
FIG. 4A is a flow chart of a page program operation according to the present invention.
FIG. 4B is a simplified schematic showing program verify circuitry according to the present invention.
FIGS. 5A-5H illustrate the steps in manufacturing a first type of flash EPROM cell according to the present invention, with an extended floating gate for improved coupling ratio.
FIGS. 6A-6G illustrate the final six steps in a sequence which begins as set out in FIGS. 5A-5D, for implementing an alternative embodiment of the flash EPROM cells according to the present invention.
FIG. 7 provides a perspective of the layout of a flash EPROM segment according to the present invention.
FIGS. 8-14 are mask layouts for implementing the flash EPROM segment of FIG. 7, in which:
FIG. 8 illustrates the layout of a first diffusion and a field oxide isolation in the substrate.
FIG. 9 illustrates the region of a p+ type cell implant for raising the threshold voltage in the cells of the array.
FIG. 10 illustrates the layout of a first polysilicon layer.
FIG. 11 illustrates the layout of a second polysilicon layer.
FIG. 12 illustrates the layout of a third polysilicon layer.
FIG. 13 illustrates the positioning of metal contacts.
FIG. 14 illustrates the layout of the overlying metal lines for the subarray.
DETAILED DESCRIPTION
A detailed description of preferred embodiments of the present invention is provided with respect to the figures, in which FIG. 1 provides an overview of the layout of a flash EPROM integrated circuit module according to the present invention. Thus, the integrated circuit module of FIG. 1 includes a flash EPROM memory array 100 coupled to a plurality of redundant memory cells 101 used for replacing failed cells in the main array as known in the art. A plurality of reference cells 102 are used with sense amps 107 for differential sensing the state of the cells in the memory array.
Coupled to the memory array 100 are word line and block select decoders 104 for horizontal decoding in the memory array. Also coupled to the memory array 100 are the column decoder and virtual ground circuit 105 for vertical decoding in the array.
Coupled to the column decoder and virtual ground circuit 105 are the program data in structures 103. Thus, the sense amps 107 and the program data in structures 103 provide data in and out circuitry coupled to the memory array.
The flash EPROM integrated circuit typically is operated in a read only mode, a program mode, and an erase mode. Thus, mode control circuitry 106 is coupled to the array 100.
Finally, according to one embodiment of the present invention, during the program and erase modes, a negative potential is applied to either the gate or source and drain of the memory cells. Thus, a negative voltage generator 108 and a positive voltage generator 109 are used for supplying various reference voltages to the array. The negative voltage generator 108 and positive voltage generator 109 are driven by the power supply voltage V CC .
FIG. 2 illustrates two segments within a larger integrated circuit. The segments are divided generally along dotted line 50 and include segment 51A generally above the dotted line 50 and segment 51B generally below the dotted line 50. A first pair 52 of columns in segment 51A is laid out in a mirror image with a second pair 53 of columns in segment 51B along a given global bit line pair (e.g., bit lines 70, 71). As one proceeds up the bit line pair, the memory segments are flipped so as to share virtual ground conductors 54A, 54B (buried diffusion) and metal-to-diffusion contacts 55, 56, 57, 58. The virtual ground conductors 54A, 54B extend horizontally across the array to a vertical virtual ground metal line 59 through metal-to-diffusion contacts 60A, 60B. The segments repeat on opposite sides of the metal virtual ground line 59 so that adjacent segments share a metal virtual ground line 59. Thus, the segment layout of FIG. 2 requires two metal contact pitches per column of two transistor cells for the global bit lines and one metal contact pitch per segment for the metal virtual ground line 59.
Each of the pairs of columns (e.g., 52, 53) along a given bit line pair comprises a set of EPROM cells. Thus, cells 75-1, 75-2, 75-N comprise a first set of flash EPROM cells in a first one of the pair 77 of columns. Cells 76-1, 76-2, 76-N comprise a second set of flash EPROM cells in the second column in the pair 77 of columns.
The first set of cells and the second set of cells share a common buried diffusion source line 78. The cells 75-1, 75-2, 75-N are coupled to buried diffusion drain line 79. Cells 76-1, 76-2, 76-N are coupled to buried diffusion drain line 80. Selector circuitry comprising top select transistor 81 and top select transistor 82 couple the respective drain diffusion lines 79, 80 to metal global bit lines 83 and 84, respectively. Thus, the transistor 81 has a source coupled to the drain diffusion line 79 and a drain coupled to a metal contact 57. Transistor 82 has a source coupled to the drain diffusion line 80 and a drain coupled to the metal contact 58. The gates of transistors 81 and 82 are controlled by the signal TBSEL A to couple the respective columns of flash EPROM cells to the global bit lines 83 and 84.
The source diffusion line 78 is coupled to the drain of select transistor 85. The source of select transistor 85 is coupled to a virtual ground diffusion line 54A. The gate of transistor 85A is controlled by the signal BBSEL A .
Furthermore, a sector of two or more segments as illustrated in FIG. 2 may share word line signals because of the additional decoding provided by the top and bottom block select signals TBSEL A , TBSEL B , BBSEL A , and BBSEL B . In one embodiment, eight segments share word line drivers, providing a sector eight segments deep.
As can be seen, the architecture according to the present invention provides a sectored flash EPROM array. This is beneficial because the source and drain of transistors in non-selected segments during a read, program or erase cycle may be isolated from the currents and voltages on the bit lines and virtual ground lines. Thus, during a read operation, sensing is improved because leakage current from segments not selected does not contribute to current on the bit lines. During the program and erase operations, the voltages of the virtual ground line, and the bit lines, are isolated from the unselected segments. This allows a sectored erase operation, either segment by segment or preferably sector by sector when the segments within a given sector share word line drivers.
It will be appreciated that the bottom block select transistors (e.g., transistors 65A, 65B) may not be necessary in a given implementation as shown in FIG. 3 below. Also, these block select transistors may share a bottom block select signal with an adjacent segment. Alternatively, the bottom block select transistors (e.g., 65A, 65B) may be replaced by single isolation transistors adjacent the virtual ground terminals 60A, 60B.
FIG. 3 illustrates an alternative architecture of the flash EPROM array according to the present invention, in which two columns of flash EPROM cells share a single metal bit line. FIG. 3 shows four pairs of columns of the array, where each pair of columns includes flash EPROM cells in a drain-source-drain configuration.
Thus, the first pair 120 of columns includes a first drain diffusion line 121, a source diffusion line 122, and a second drain diffusion line 123. Word lines WL0 through WL63 each overlay the floating gates of a cell in a first one of the pairs of columns and a cell in the second one of the pairs of columns. As shown in the figure, a first pair 120 of columns includes one column including cell 124, cell 125, cell 126, and cell 127. Not shown are cells coupled to word lines WL2 through WL61. The second one of the pair 120 of columns includes cell 128, cell 129, cell 130, and cell 131. Along the same column of the array, a second pair 135 of columns is shown. It has a similar architecture to the pair 120 of columns except that it is laid out in a mirror image.
Thus, as can be seen, the transistor in the first one of the pair of columns, such as the cell 125, includes a drain in drain diffusion line 121, and a source in the source diffusion line 122. A floating gate overlays the channel region between the first drain diffusion line 121 and the source diffusion line 122. The word line WL1 overlays the floating gate of the cell 125 to establish a flash EPROM cell.
The column pair 120 and column pair 135 share an array virtual ground diffusion 136 (ARVSS). Thus, the source diffusion line 122 of column pair 120 is coupled to the ground diffusion 136. Similarly, the source diffusion line 137 of column pair 135 is coupled to the ground diffusion 136.
As mentioned above, each pair 120 of columns of cells shares a single metal line. Thus, a block right select transistor 138 and a block left select transistor 139 are included. The transistor 139 includes a source in the drain diffusion line 121, a drain coupled to a metal contact 140, and a gate coupled to the control signal BLTR1 on line 141. Similarly, the right select transistor 138 includes a source in the drain diffusion line 123, a drain coupled to the metal contact 140, and a gate coupled to the control signal BLTR0 on line 142. Thus, the select circuitry, including transistors 138 and 139, provides for selective connection of the first drain diffusion line 121 and a second drain diffusion line 123 to the metal line 143 (MTBL0) through metal contact 140. As can be seen, column pair 135 includes left select transistor 144 and right select transistor 145 which are similarly connected to a metal contact 146. Contact 146 is coupled to the same metal line 143 as is contact 140 which is coupled to column pair 120. The metal line can be shared by more than two columns of cell with additional select circuitry.
The architecture shown in FIG. 2 and 3 is based upon a drain-source-drain unit forming two columns of cells which are isolated from adjacent drain-source-drain units to prevent leakage current from adjacent columns of cells. The architecture can be extended to units of more than two columns, with appropriate tolerances for leakage current in the sensing circuitry, or other controls on current leakage from unselected cells.
Column pairs are laid out horizontally and vertically to provide an array of flash EPROM cells comprising M word lines and 2N columns. The array requires only N metal bit lines each of which is coupled to a pair of columns of flash EPROM cells through select circuitry, as described above.
Although the figure only shows four column pairs 120, 135, 150, and 151, coupled to two metal bit lines 143 and 152 (MTBL0-MTBL1), the array may be repeated horizontally and vertically as required to establish a large scale flash EPROM memory array. Thus, column pairs 120 and 150 which share a word line are repeated horizontally to provide a segment of the array. Segments are repeated vertically. A group of segments (e.g., eight segments) having respective word lines coupled to a shared word line driver may be considered a sector of the array.
The layout of the array is compact because of the virtual ground configuration, the reduced metal pitch requirement for the layout, and further by the ability to share word line drivers amongst a plurality of rows in different segments. Thus, word line WL63' may share a word line driver with word line WL63. In a preferred system, eight word lines share a single word line driver. Thus, only the pitch of one word line driver circuitry is needed for each set of eight rows of cells. The additional decoding provided by the left and right select transistors (139, 138 for segment 120) allows the shared word line configuration. The shared word line configuration has the disadvantage that during a sector erase operation, eight rows of cells all receive the same word line voltage, causing a word line disturbance in cells that are not desired to be erased. If it is a problem for a given array, this disturbance problem can be eliminated by insuring that all sector erase operations decode for segments including all rows of cells coupled to the shared word line drivers. For eight word lines sharing a single driver, a minimum sector erase of eight segments may be desired.
FIG. 4 is a schematic block diagram of a flash EPROM array meant to illustrate certain features of the present invention. Thus, the flash EPROM memory module shown in FIG. 4 includes a main flash EPROM array, including sectors 170-1, 170-2, 170-3, 170-N, each sector including eight segments (e.g., SEG0-SEG7). A plurality of sets of shared word line drivers 171-1, 171-2, 171-3, 171-N are used to drive the shared word lines of the eight segments in the respective sectors. As illustrated with respect to shared word line drivers 171-1, there are 64 shared drivers for sector 170-1. Each of the 64 drivers supplies an output on line 172. Each of these outputs is used to drive eight word lines in respective segments of the sector 170-1 as schematically illustrated in the figure by the division into eight sets of 64 lines.
Also coupled to the array are a plurality of block select drivers 173-1, 173-2, 173-3, 173-N. The block select drivers each drive a left and right block select signal for each segment. Where the segments are implemented as shown in FIG. 3, there is a BLTR1 and BLTR0 block select signal pair supplied for each set of 64 word lines.
In addition, there are N global bit lines in the flash EPROM array. The N bit lines are used to allow access to the 2N columns of flash EPROM cells in the array for the data in circuitry and sense amps 191. The N bit lines 174 are coupled to a column select decoder 175. Similarly, the block select drivers 173-1 through 173-N are coupled to a block decoder 176. The shared word line drivers 171-1 through 171-N are coupled to row decoder 177. The column select decoder 175, block decoder 176, and row decoder 177 receive address signals on the address in line 178.
Coupled to the column select decoder 175 is page program buffer 190. The page program buffer 190 include N latches, one for each of the N bit lines. Thus, a page of data may be considered N bits wide, with each row of cells two pages, page 0 and page 1, wide. Pages in a given row are selected using the left and right decoding described above.
Selectable voltage sources 179 are used to supply the reference potentials for the read only, program, and erase modes for the flash EPROM array as conceptually illustrated in the figure, through the word line drivers 171-1 to 171-N and through the bit lines.
The virtual ground lines in the array are coupled to the virtual ground driver 181 which is coupled with the array. Also, p-well and n-well reference voltage sources 199 are coupled to the respective wells of the array.
Thus, as can be seen in FIG. 4, the 64 word line drivers, such as word line drivers 171-1, are used with 512 (64×8) rows in the array. The additional decoding provided by the block select drivers (e.g., 173-1) allow for the shared word line layout.
The architecture of the flash EPROM array, according to the present invention, allows for row redundancy as schematically illustrated in FIG. 4. Thus, the W bit lines extend from the main array across lines 182 to a redundant array including sectors 183-1 and 183-2. The redundant array is driven by the redundant word line drivers 184-1 and 184-2. Similarly, redundant block select drivers 185-1 and 185-2 are coupled to the redundant array.
If, during testing, a cell on a given row is found defective, that row and the seven other rows which share the word line driver may be replaced by corresponding rows in the redundant array 183-1 and 183-2. Thus, the system would include a content addressable memory (CAM) cell 198 with a redundant decoder 186 which receives the address data. As known in the art, during testing, failed rows in the main array are identified, and the address of such rows is stored in the CAM cell 198. When the address ADDR IN on line 178 matches the address stored in the CAM cell 198, then a match signal is generated on line 187. The match signal disables the shared word line drivers 171-1 through 171-N in the main array. The redundant decoder 186 drives the redundant word line drivers 184-1 and 184-2, and drives redundant block select drivers 185-1 and 185-2 to select the appropriate replacement row.
The redundant row decoding may also be coupled with redundant column decoding, as known in the art, to provide a flash EPROM array with much greater manufacturing yield.
The column select decoder 175 is coupled to the page program latches 190, including at least one latch for each of the N bit lines. Also, the column select decoder 175 is coupled to the data in circuitry and sense amps 191. Together, these circuits provide data in and out circuitry for use with the flash EPROM array.
Redundant row decoding also provides capability of correcting for shorts between adjacent word lines. In particular, when two word lines are shorted, two word lines must be replaced with corresponding two word lines in the redundant array. In the embodiment described, where there are eight word lines sharing a common word line driver, two sets of eight word lines are used to replace a corresponding two sets of eight word lines in the main array. Thus, the two shorted word lines in the main array can be repaired with row redundancy.
The cells in the preferred embodiment are configured for a sector erase operation that causes charging of the floating gate (electrons entering the floating gate) such that upon sensing an erased cell, the cell is non-conducting and the output of the sense amp is high. Also, the architecture is configured for a page program which involves discharging a floating gate (electrons leaving the floating gate) such that upon sensing, a programmed cell is conducting.
The operation voltages for the programming operation are positive 5 volts to the drain of a cell to be programmed to a low (data=0) threshold condition, negative 10 volts to the gate, and 0 volts or floating of the source terminal. The substrate or the p-well 200 shown in FIGS. 5G and 6H is grounded. This results in a Fowler-Nordheim tunneling mechanism for discharging the floating gate.
The erase operation is executed by applying negative 6 volts to the drain, positive 12 volts to the gate, and negative 6 volts to the source. The p-well 200 is biased at negative 6 volts. This results in a Fowler-Nordheim tunneling mechanism to charge the floating gate. The read potentials are 1.2 volts on the drain, 5 volts on the gate, and 0 volts on the source.
This sets up the ability to do a sector erase using word line decoding to select cells to be erased. The erase disturbance condition for unselected cells within a segment results in -6 volts on the drain, 0 volts on the gate, and -6 volts on the source. This is well within the tolerances of the cells to withstand these potentials without causing significant disturbance of the charge in the cell.
Similarly, the program disturbance conditions, for cells which share the same bit line in the same segment are 5 volts on the drain, 0 volts on the gate, and 0 volts or floating on the source. There is no gate to drain drive in this condition and it does not disturb the cell significantly.
For cells which share the same word line but not the same bit line or an addressed cell which is to remain in a high condition, the disturbance condition is 0 volts on the drain, -10 volts on the gate, and 0 volts or floating on the source. Again, this condition does not result in significant deterioration of the charge in the unselected cells.
The two well technology is critical so that the negative voltage can be applied to the drain and source diffusion regions. Without the negative voltages on the source and drain, the gate potential for a cell with a 50% coupling ratio, requiring about 9 volts across the floating gate/drain junction, must be about 18 volts. These very high voltages on integrated circuits require specially designed circuits and special process technology. Similarly, the negative voltage on the gate allows lower positive potentials on the drain for the program operation.
FIG. 4A is a flow chart illustrating the program flow for the flash EPROM circuit of FIG. 4. The process begins by erasing the sector (e.g., sector 70-1) into which data is to be programmed (block 600). After erasing the sector, an erase verify operation is executed (block 601). Next, the page number, either 0 or 1, and the segment number, 1-8, is set by the host processor in response to the input address (block 602).
After setting the page number and segment number, the page buffer is loaded with the data for the page (block 603). This page buffer may be loaded with an entire N bits of data, or a single byte of data, as suits a particular program operation. Next, a verify operation is executed, in case the user does not pre-erase, to determine which cells need programming (block 604). After loading the page buffer, the program potentials are applied to the segment being programmed (block 605). After the program operation, a verify operation is executed in which the page is verified. In the verify operation, the bits in the page buffer which correspond to successfully programmed cells are turned off (block 606). Next, the algorithm determines whether all page bits are turned off in the page buffer (block 607). If they are not all off, then the algorithm determines whether a maximum number of retries has been made (block 610), and if not, loops to block 605 to program the page again, such that the failed bits are reprogrammed. The bits which pass are not reprogrammed because the corresponding bits in the page buffer were reset to 0 during the verify operation. If the maximum number of retries has been made at block 610, then the algorithm hangs up, signaling an unsuccessful operation.
If at block 607, all page bits were off, then the algorithm determines whether the sector has been finished, that is, whether both pages of the sector are to be written and both are completed (block 608). This is a CPU determined parameter. If the sector is not finished, then the algorithm loops to block 602 and updates the appropriate one of the page number or segment number.
If the sector has been finished at block 608, then the algorithm is done (block 609).
As mentioned with respect to block 605 of FIG. 4A, the program verify circuitry involves resetting on a bit by bit basis, the data in the page buffer which passes erase verify. Thus, a structure such as shown in simplified form in FIG. 4B is included in the flash EPROM. The sense amps 650 of the array are coupled to a compare circuitry 651. The inputs to the compare circuitry are the page buffer latches 652. Thus, a byte of data from the sense amps is compared against a corresponding byte from the page buffer. A pass/fail signals for the byte are fed back to a bit reset on the page buffer 652. Thus, bits which pass are reset in the page buffer. When all bits in the page buffer are reset, or a set number of retries of the program operation has been accomplished, then the program operation is complete.
FIGS. 5A-5H illustrate manufacturing steps for a flash EPROM array according to one embodiment of the present invention. FIGS. 5A-5G are not drawn to scale. FIG. 5H is an approximate scale drawing to provide perspective for the resulting structure. FIGS. 6A-6G provide an alternative approach to manufacturing the flash EPROM cell, which involves the same initial steps, as illustrated in FIGS. 5A-5D. As with FIG. 5H, FIG. 6G is an approximate scale drawing of the resulting structure. FIGS. 7 and 8-14 are used to describe the layout of a three word line by six column test array for the embodiment described with respect to FIGS. 5A-5H, and FIG. 3.
The process of FIGS. 5A-5H will be described first. The cell is fabricated using a 0.6 micron CMOS double metal, triple well (two wells in the array, a third for peripheral circuitry), and triple poly technology. The primary steps involved in manufacturing the cell are shown in FIGS. 5A-5H.
FIG. 5A illustrates the first step in the process. Starting with a p-type silicon substrate 200 (or region of the substrate), a deep n-type well 198, around 6 microns in depth is formed. Next, a p-well 199, around 3 microns in depth, is formed inside the n-well.
The deep n-well 198 is formed first by implanting an n-type dopant into the substrate where the n-well region is defined by a photoresist mask. After implant, the photo mask is removed and the substrate is annealed at high temperature for a relatively long time to drive in and activate the n-type dopant to form the deep well. Then, a similar process is formed to implement a p-well inside the deep n-well.
In the next step, a well known LOCOS field oxidation process is used to grow relatively thick field oxide regions 201 and 202 which are elongated in a direction perpendicular to the page. Also, a sacrificial oxide layer is grown and then removed to prepare the surface of the p-well 199 for subsequent steps.
As illustrated in FIG. 5B, a thin tunnel oxide 203 is grown about 90 Å thick. As illustrated in FIG. 5C, a first layer poly 204 is deposited of about 800 Å on top of the tunnel oxide 203. Then, a thin nitride layer 205 of about 200 Å is deposited on top of the poly layer 204.
As illustrated in FIG. 5D, a photomasking process is used to define the floating gates, and n+ source and drain diffusion regions. Thus, photomask layers 206, 207 are defined to protect the floating gate regions in poly one 204. The poly one 204 and nitride layers 205 are etched away except as protected by the masks 206 and 207 to expose the drain, source and drain regions. Next, n-type dopants are implanted in the p-well 199 as illustrated at arrows 208 within the exposed regions. These regions are therefore self-aligned to the floating gate in poly one 204 and to the field isolation regions 201 and 202.
As illustrated in FIG. 5E, the substrate is annealed to activate the dopants and define the drain diffusion regions 213 and 214, and the source diffusion region 215. Also, drain oxides 216, 217 and source oxide 218 of about 2,000 Å are grown, along with oxides 225 and 226 covering the sides of the floating gate poly 204.
In the next step, the nitride layer 205 on the floating gates is removed and then a second layer 219 of poly (poly two) is deposited over the first layer. The second layer 219 is about 800 Å thick and deposited on top of poly one. This layer is implanted with an n-type dopant.
As shown in FIG. 5F, a photomasking process is used to define the poly two pattern, which in turn defines the effective floating gate area as seen from the control gate to be deposited in poly three. The effective floating gate area is increased by the poly two deposition so that the coupling ratio is high enough and preferably about or larger than 50%. During following high temperature annealing steps, the n-type dopants will uniformly distribute between poly two and poly one layers, resulting in very low resistance contact between the two layers.
As illustrated in FIG. 5G, an ONO layer 220 is grown on top of the poly two layer. The ONO layer is about 180 Å thick. Finally, a third poly layer 221 (poly three) is deposited on top of the ONO and, after deposition of tungsten silicide as shown in FIG. 5H, etched to define the word line for the memory cells.
FIG. 5H illustrates the layer of tungsten silicide 234 over the poly three layer 221 used to improve the conductivity of the word lines. FIG. 5H is an approximate scale sketch of the structure of the resulting cell. According to the process of FIGS. 5A-5H, the drain diffusion region 213 is formed in a region between the field oxide 202 and the poly one layer of the floating gate 230, which is about 0.6 microns wide. Similarly, the poly one portion of the floating gate 230 is about 0.6 microns wide. The source diffusion region between floating gate regions 230 and 232 is approximately 1.0 microns wide. The drain diffusion region 214 is approximately 0.6 microns wide.
The 1.0 micron wide source diffusion region 215 is formed slightly wider to allow for alignment tolerances for the poly two deposition process. With a more controlled alignment process, the width of the source diffusion region 215 can be reduced.
The vertical dimensions of the various elements are shown in approximate scale in FIG. 5H. Thus, the tunnel oxide 203 under the poly one portion of the floating gate electrode 230 or 232 is approximately 90 angstroms thick. The poly one deposition 230 is approximately 800 angstroms thick. The oxide region 216 over the drain diffusion region 213, and similarly the oxides over the source diffusion region 215 and drain diffusion region 214 as grown are approximately 2,000 to 2,500 angstroms thick, but as finished are in the range of 1,000 to 1,500 angstroms.
The side wall oxide 226 on the poly one portion of floating gate 230 is in the range of 600 angstroms thick. As can be seen in the sketch, it merges with the thermal oxide 216 over the source or drain diffusion region as appropriate.
The thickness of the second poly deposition 231 is approximately 800 angstroms. The thickness of the ONO layer 220 is approximately 180 angstroms. The third poly layer 221 is approximately 2,500 angstroms thick. The tungsten silicide layer 234 is approximately 2,000 angstroms thick. The field oxide region 202 in the finished product is in the range of 6,500 to 5,000 angstroms thick.
FIG. 5H illustrates a feature of the process of FIGS. 5A-5H. As can be seen, in FIG. 5G, the second poly deposition 233 only partially covers the drain diffusion region 214. In FIG. 5H, an alternative mask is used to extend the poly two portion of the floating gate across the drain diffusion region partially overlapping the field oxide region 202. This variability in the process allows the coupling ratio of the floating gate to be varied as suits the needs of a particular design by extending its length out over the field oxide region.
Metallization and passivation layers (not shown) are deposited over the circuit of FIG. 5H.
Thus, as can be seen in FIG. 5H, a floating gate structure for a drain-source-drain configured flash EPROM segment is provided which consists of a first layer polysilicon 230 and a second layer polysilicon 231. The first layer poly 230 is used for self-alignment of the source and drain diffusion regions. The second layer poly 231 is used to extend the floating gate surface area to increase the coupling ratio of the cell.
In the drain-source-drain configuration, it can be seen that the floating gate consisting of poly one layer 230 and poly two layer 231 for the cell on the left side, and the floating gate consisting of poly one layer 232 and poly two layer 233 for the cell on the right side of the figure are essentially mirror images. This allows for extension of the floating gate out over the drain diffusion regions in the drain-source-drain configuration, without shorting over the shared source diffusion region substantially.
The cell technology and layout has a number of merits. The tunnel oxide is grown before the array source/drain implant. Thus, oxide thickening and dopant depletion effects are minimized. The source and drain implant of the memory cell is self-aligned to the poly one pattern. Thus, the channel length of the cell can be well controlled.
There is a relaxed metal design rule can be used with the flash array, particularly in the architecture of FIG. 3. The source block transistor merges with the memory cell source/drain diffusion in the cell layout. This overlap region provides interconnection between these two diffusion areas. The field oxide is used to isolate the bit line pairs from neighboring bit lines. Inside the bit line pair, the structure is flat.
Also, for the cell illustrated in FIGS. 5A-5H, the effective gate coupling area seen from the control gate is determined by the area of the second layer of poly. Therefore, a reasonably high gate coupling ratio can be achieved by extending the second layer of poly over the buried diffusion or field oxide regions to compensate for the low gate coupling ratio which would be provided by only the first layer of poly. Further, by extending the length of the extension of the second layer of poly out over the diffusion regions and isolation regions, different gate coupling ratios can be easily achieved to meet different product applications.
An alternative cell structure is illustrated with respect to FIGS. 6A-6G. This structure begins with the same manufacturing steps as shown in FIGS. 5A-5D above. Thus, as can be seen in FIG. 6A, the sequence proceeds from the structure of FIG. 5D by first removing the masks 206 and 207, and then depositing a nitride layer 250 over the region. The nitride layer coats the sides of the floating gate poly 204 as illustrated in the figure.
In the next step, as shown in FIG. 6B, an anisotropic etch is used to remove the deposited nitride layer 250, except for those portions of the layer on the top and sides of the floating gate poly 204.
The etch may leave a small amount of nitride on the edges of the field oxide regions 201, 202. However, this is not important to the process.
After the anisotropic etch of the nitride, the wafer is annealed to drive-in the dopants to form the drain diffusion regions 213 and 214 and the source diffusion region 215. Also, the thermal oxides 216, 217, and 218 are grown over the drain diffusion regions and the source diffusion region, respectively. The nitride layers 205 and 250 protect the floating gate poly 204 from oxide formation.
In the next step, as shown in FIG. 6C, the nitride remnants of the layer 205 and the layer 250 are removed from the structure, exposing the poly one floating gate elements 204.
In the next step, as shown in FIG. 6D, a second poly deposition 219 is deposited on the structure. This second layer poly 219 is deposited to a thickness of about 1,500 to 2,000 angstroms and implanted with an n-type dopant.
As shown in FIG. 6E, poly spacers 240 and 241 are formed along the edges of the poly one pattern using a self-aligned plasma etching of the poly two layer.
During following high temperature steps, the n-type dopants in the poly two deposition will distribute evenly between the poly one and poly two elements, and provide good electrical contact.
As illustrated in FIG. 6F, an ONO layer 220 is deposited over the floating gate structures formed of the poly one element, 242, and the poly two spacers 240 and 241. Also, a region of polysilicon 243 may be left adjacent the field oxide region 201 in this process. However, there is no electrical contact in this region and it should not have an affect on the operation of the device. After deposition of the ONO layer 220, a third poly layer 221 is deposited having a thickness of about 2,500 angstroms to form the word lines for the device.
FIG. 6G illustrates the last step in the process of depositing a layer of tungsten silicide 234 having a thickness of about 2,000 angstroms over the poly three word line 221 to improve the conductivity of the structure.
FIG. 6G is also an approximate scale sketch of the structure. Thus, as can be seen, the drain diffusion regions 213 and 214 are formed in a region between a field oxide 202 and the floating gate 204 of about 0.6 microns in width. The floating gate poly one deposition 204 is about 0.15 microns in thickness. Also the source diffusion region 215 formed between the poly one floating gates is about 0.6 microns in this embodiment. The narrower source diffusion region 215 as compared to that of FIG. 5H, is possible in this approach because of the self-aligned nature of the poly two spacers 240 and 241. There is no need in a layout of a structure as shown in FIG. 6G to provide for mask misalignment tolerances necessary for aligning the mask to form the poly two floating gate extensions of FIG. 5H. This makes the structure of FIG. 6G scalable, as process dimensions shrink, without requirement for allowing for mask misalignment tolerances.
The thicknesses of the regions in the vertical dimensions are similar to those of FIG. 5H. However, the poly one deposition 242 is about 1,500 to 1,600 angstroms thick. The spacers 240 and 241 extend about 2,000 angstroms out over the source and drain diffusion regions.
In an alternative process for making a structure such as shown in FIG. 6G, the second nitride layer 250 is not deposited. However, during the anneal step of FIG. 6B, oxide will grow on the side of the poly one deposition. These oxides on the sides of the poly can be etched away, so that contact between poly one and poly two may be provided in the subsequent steps. However, the etching of the oxide on the side of the poly one portion of the floating gate, will risk etching of the oxide between the floating gate and the substrate. If this region is etched too far, then a short may occur during the poly two deposition to the substrate. Thus, the procedure illustrated in FIG. 6A-6G may be preferred for many applications.
The polysilicon used in the described structure for the floating gate can be replaced with amorphous silicon.
For a better understanding of the layout of the integrated circuit according to the present invention, FIGS. 7-14 are used to describe the layout of a test array which is 6 columns by 3 word lines in size. FIG. 7 is a composite view which will be understood better with reference to the layout views of FIGS. 8-14. As can be seen in FIG. 7, the test array includes five field isolation regions 400, 401, 402, 403, and 404. The layout of these isolation regions can be seen with reference to FIG. 8 where the field oxide regions are marked with reference numerals 400-404, and the hatched region 405 corresponds to an active region inside the p-type well 199 of FIG. 5G.
FIG. 9 illustrates the layout of a p-type implant which is used to raise the threshold voltage VT of the memory cells. The implant in area 406 causes a higher initial VT for the memory cells in the block than for the select transistors (in regions circled by lines 436 and 437 of FIG. 7).
The array also includes the poly three control lines 407 and 408 for the right and left select transistors for each of the three segments, respectively. FIG. 7 also shows three word lines 409, 410, and 411 which overlay three segments of the array. The first layer poly is illustrated in FIG. 7 by the bold outline 415 and is also more clearly seen in FIG. 10. There are segments 416, 417, 418, 419, 420, and 421 in the first layer poly, as illustrated in FIG. 10, used for self-alignment of the left and right select transistors. These segments are later removed, after formation of the source and drain regions of the cells. Thus, FIG. 10 illustrates the masking for the poly one deposition. Poly one is deposited and etched inside the region defined by the line 415, and in the regions surrounding the layout on FIG. 10, to establish the first layer poly of the floating gates of FIG. 5G.
FIG. 11 illustrates the masking pattern for the second layer poly for the cell illustrated in FIG. 5G. Regions 412, 413, and 414 are apparent in FIG. 7. Regions 422 and 423 correspond to segments of the floating gate poly over the field isolation areas 401 and 403 of FIG. 7. Poly two is later patterned to establish the extended floating gate of FIG. 5G.
FIG. 12 illustrates the layout of the poly three control lines 407 and 408 and the word lines 409, 410, and 411.
FIG. 13 illustrates the metal contacts 424, 425, 426, 427, 428, and 429 in the test array. The contact 424 is used to contact the poly three control line 408. The contact 428 is used for making a metal contact to the poly three control line 407. Contacts 425, 426, and 427 are used for making contact from the diffusion region of the select transistors to the metal global bit lines which overlay the array (not shown in FIG. 7). Contact 429 is used for making contact to the array source diffusions. The layout of the metal lines is shown in FIG. 14. As can be seen, they align with the contacts 425, 426, and 427 and overlay the segments in the array. Thus, metal bit line 430 is coupled to contact 425, metal bit line 431 is coupled to contact 426 and metal bit line 432 is coupled to contact 427. The metal pads 433 and 434 are coupled to contacts 428 and 424, respectively. The metal pad 435 is coupled to contact 429.
Thus, in the sequence a field isolation and diffusion step is shown in FIG. 8. Next, a VT enhancement implant step is carried out in the region 406 shown in FIG. 9. Next, the floating gate poly is laid down. In addition, the segments 416 through 421 are laid down with poly one to establish the channels for the left and right block select transistors. Then a source/drain implant is executed to form the drain-source-drain structure and the buried diffusions for the left and right block select transistors and the virtual ground terminal. After this implant, the poly two is deposited, as illustrated in FIG. 11. Poly two is patterned as described above to establish the extended floating gates. An insulating layer is placed over poly two and the third layer of poly is deposited with a pattern as shown in FIG. 12. Finally, isolation is deposited over the poly three layer, the metal contacts are made, and the metal bit lines are deposited overlaying the array.
As can be seen in FIG. 7, the left select transistor underlies the control line 408 in the region circled by line 436. Similarly, the right select transistor for the first segment underlies the control line 407 in the region circled by line 437. The contact 425 reaches a diffusion region 438. The diffusion region 438 is isolated from a diffusion region 439 by the masked area 440 which was defined by the poly one deposition. Similarly, the diffusion region 438 is isolated from diffusion region 441 by the masked area 442 which was masked by the poly one deposition. Thus, a select transistor for the left column is established across the channel defined by region 442. The diffusion region 441 is within or coupled to the drain diffusion region for the segment. Similarly, the diffusion region 439 is within or coupled to the right side drain diffusion region for the segment.
The current path from the contact 425 to the left diffusion region for the segment is illustrated by the arrow line 443. As can be seen, this path is interrupted by the transistor channel in the region 442. Thus, the control line 408 provides for connection of the left drain diffusion region to the contact 425.
The current path for the right block select transistor is illustrated by the arrow line 444. As can be seen, this path is interrupted by the channel in the region 440. The two select transistors in the regions 436 and 437, thus provide for selective connection of the contact 425 to either the left or right diffusion region. This way, two columns of flash EPROM cells are selectively coupled to a single metal bit line via contact 425.
As will be appreciated by those skilled in the art, the mask sequence of FIGS. 8-14 will be altered for the cell illustrated in FIG. 6H as concerns the poly 2 deposition steps. However, the basic layout of the array remains unchanged.
Accordingly, a new flash EPROM cell and array architecture have been provided. The architecture provides for a very dense core array obtained by unique cell layouts, where two adjacent local drain bit lines share one common source bit line. Also, the layout has been optimized to allow use of a single metal line for every two columns of cells in the array. Further, the layout is further reduced by shared word lines, so that the word line driver pitch does not impact the size of the main array. Sector erase is feasible using segmentable architecture of the present invention. Also, row redundancy is available for flash EPROM using this structure. A high performance, reliable flash memory array can be achieved using these technologies.
An n-channel embodiment of the flash EPROM array has been disclosed. Those skilled in the art will recognize that p-channel equivalent circuits can be implemented using techniques known in the art. Furthermore, the architecture has been designed with respect to flash EPROM cells. Many aspects of the architecture may be adapted to a variety of memory circuit arrays.
The foregoing description of a preferred embodiment of the invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise forms disclosed. Obviously, many modifications and variations will be apparent to practitioners skilled in this art. It is intended that the scope of the invention be defined by the following claims and their equivalents. | Contactless flash EPROM cell and array designs, and methods for fabricating the same result in dense, segmentable flash EPROM chips. Also, an extended floating gate structure, and method for manufacturing the extended floating gate allow for higher capacitive coupling ratios in flash EPROM circuitry with very small design rules. The floating gates are extended in a symmetrical fashion in a drain-source-drain architecture, so that each pair of columns of cells has a floating gate which is extended in opposite directions from one another. This allows one to take advantage of the space on the cell normally consumed by the isolation regions, to extend the floating gates without increasing the layouts of the cells. Also, an easily scalable design is based on establishing conductive spacers on the sides of floating gate deposition layers which are used for self-alignment of the source and drain. According to this structure, a floating gate deposition is first laid down and used for establishing self-aligned source and drain diffusion regions. After deposition of the source and drain, conductive spacers are deposited on the sides of the first floating gate structure. These conductive spacers can be deposited in a symmetrical fashion, and are easily scalable to large scale arrays of flash EPROM designs. | 7 |
FIELD OF THE INVENTION
[0001] The invention relates to a camouflage shelter having a collapsible self-supporting subframe.
BACKGROUND OF THE INVENTION
[0002] U.S. Pat. No. 3,968,808 has disclosed a collapsible, self-supporting structure which is constructed from a lattice of poles that are coupled at their ends in an articulated manner and form scissor-like pairs, at the intersections of which the poles are rotatably connected. The lattice in this case consists of numerous such pairs, each of which forms inner and outer end points and bearing points at which, in each case, groups of radially extending poles are rotatably coupled to one another. The outer bearing points lie on a surface of rotation or element of a surface of rotation, such as, for example, a section of a sphere. The inner bearing points lie on a surface comparable thereto and extending parallel at a distance.
[0003] Such a structure can be packed very small and forms a mobile unit which can be assembled very quickly, easily and simply, without major effort, in that the ends of the structure in question are pulled apart, the lattice thus unfolding and forming the stable, self-supporting structure. Various geometrical shapes of the overall structure are possible here, though hemispherical constructions or constructions in the nature of a tunnel section have proven their value as regards high stability.
[0004] These constructions are used as a tent or roofing, the material forming the roofing or the tarpaulin being fixedly connected to the outer end points and bearing points so that the corresponding structure is available as a roofing or tent immediately after assembly.
[0005] DE 40 23 287 C2 has disclosed a camouflage net comprising a polyester mesh with a perforated structure. This camouflage net, because of its structure, with the holes that can have a diameter or a width and/or height of about 2 to 3 mm and whose distance from one another is approximately of the same order of magnitude, the metal fibers incorporated into the mesh, and the fact that the mesh is provided with a polymer coating on both sides containing about 30 to 40% by weight of absorbent pigments active in the range from 10 to 100 GHz, offers a very good camouflage effect.
[0006] Such a camouflage net, when used appropriately, offers a very good camouflage effect not only optically but also in the range of infrared cameras or thermal image sensors, and in the range of radar detection, especially in the millimeter and centimeter radar radiation range. The camouflage nets are positioned over appropriate stationary or mobile military equipment, such as motor vehicles, tanks or the like, and then stretched on the appropriate vehicles over supporting elements which ensure a distance between the camouflage net and the vehicle and so disguise the outline of the vehicle. In such cases, free space is formed between the camouflage net and the object to be camouflaged, permitting convective heat exchange and necessary to provide camouflage against thermal imaging equipment. This, however, results in a very complex construction which greatly restricts the mobility of the camouflaged object, especially in the case of a motor vehicle or tank.
SUMMARY OF THE INVENTION
[0007] It is therefore an object of the present invention to provide a construction for camouflaging mobile military equipment, such as motor vehicles, tanks or weapons systems but also individuals, command posts and the like, that ensures good mobility of the corresponding military equipment, which can be quickly camouflaged and which, despite its camouflage, allows rapid reaction to hostile acts of aggression.
[0008] This object is achieved, according to the invention, in that an appropriate collapsible, self-supporting subframe, as described in U.S. Pat. No. 3,968,808, is combined with a camouflage net arranged loosely over this subframe as described in DE 40 23 287 C2.
[0009] The inventors have discovered the surprising and non-obvious fact that a camouflage shelter of this kind can be ideally produced from a combination of the abovementioned subframe with the abovementioned camouflage net. If the subframe is used without a tent roof or the like arranged over it, a very open construction results which is ideally suited to being covered by the corresponding camouflage net. The effect of the geometrical arrangement created by the construction, with its inner and outer bearing points, is that a distance is always ensured between the camouflage net and the object to be camouflaged, acting as a corresponding radiation source. Because of the parallel distance between the surfaces defined by the outer bearing points and those defined by the inner bearing points, at least that distance must always exist between the object to be camouflaged and the camouflage net.
[0010] It is thus possible to ensure that, because of the perforated structure of the camouflage net, appropriate heat convection can always take place, and that the metallic pigments incorporated in the camouflage net and other absorbent substances can thus produce their ideal effect.
[0011] As a result of the fact that the camouflage shelter according to the invention does not entail any permanent connection between the subframe and the camouflage net, various advantages arise. One very significant advantage lies in the fact that a subframe of this kind can always be carried, for example, on vehicles, the camouflage net, which is packed separately from the subframe and may also be stored separately, being very easily and simply adaptable to the respective areas of use, for example woodland, town, desert, winter conditions or the like. This therefore makes it possible to operate with differently printed camouflage nets for each of the different areas of use, while only relying on one of the subframes for each of the mobile equipment units.
[0012] This possibility can be ideally exploited with the camouflage shelter according to the invention, as the camouflage net used has a very small perforated structure whose holes have a diameter of only a few millimeters. When drawn over the subframe, therefore, the camouflage net cannot become hooked up on the latter or on its outer end points, as a conventional camouflage net would do. The advantage of the two-part construction with its logistical and tactical benefits can therefore only be used so simply with the combination according to the invention. The camouflage shelter according to the invention can be assembled completely independently of the object to be camouflaged, in particular a mobile military equipment item, and so offers the option of being used as a “camouflage garage”. The mobility of the camouflaged equipment and its rapid tactical reaction capability are not significantly reduced thereby in comparison with an uncamouflaged, unobstructed equipment item.
[0013] The modular assembly of the “camouflage garage” enables larger camouflage shelters comprising a plurality of individual units to be assembled. In addition to tunnel-shaped subframes of various sizes, igloo-shaped or differently assembled subframes can also be used.
[0014] If such subframes of different shapes and sizes are assembled to form a larger camouflage shelter, this results, particularly advantageously, in a very nonuniform shape or a very uneven silhouette. This very uneven and therefore more natural-seeming shape of such a large camouflage shelter consisting of a plurality of modules is very advantageous for camouflage purposes, because its unevenness makes it adapt very easily to the general natural environment and makes it less readily identifiable optically.
[0015] When used in urban surroundings, this advantage can of course be utilized in an analogous manner, as in this case it becomes possible, by using appropriately symmetrical and relatively linear constructions, by combining a plurality of subframes, to obtain a shape or silhouette which adapts very well to the customary urban scene with its frequent occurrence of straight edges.
[0016] In addition to the camouflage net described above, or alternatively instead of the camouflage net described above, it is also possible, depending on the desired disguise effect, to use a material here which is described in DE 199 52 521.8 in connection with the production of breathable protective clothing. This material can screen heat sources located under the camouflage shelter against detection with thermal imaging equipment or the like and can be used with the camouflage net or, optionally, instead of the camouflage net. It is, however, also conceivable to secure this material as a fabric or tarpaulin to the inner bearing points in order thus to achieve the protection customary in the case of a tent or the like.
[0017] Since this material permits, especially, EMC protection against electromagnetic waves and the like, it can be used effectively to prevent attempts to jam or listen in on corresponding electronically based communication or control systems installed in the camouflage shelter. In a particularly advantageous embodiment of the invention, the camouflage net in question can have a different camouflage print on one surface from that on its other surface. This gives rise to further logistical advantages, since in this case, using only one camouflage net and the subframe of which only one is needed in any case for each mobile military equipment item to be camouflaged, two different camouflages are possible. Thus, for example, very rapid reaction is possible, in the case of an operation conducted in appropriately wooded terrain, to meteorological changes such as, for example, the onset of winter and a change in the landscape caused by snowfall. Comparable advantages will also arise, for example, if operations are planned both in wooded terrain and in urban or desert surroundings. In a further very advantageous embodiment of the invention, a tarpaulin or an equivalent layer providing protection against precipitation and the effects of weather is provided at the inner bearing points of the subframe. This layer can be designed as an independent tarpaulin, which can be suspended inside this subframe as required.
[0018] As a result of the construction of the subframe, the advantage again arises here that a distance exists, in this case between the tarpaulin and the camouflage net drawn over the outer contact points of the subframe, so that all camouflage effects provided by the camouflage net, but especially those directed against thermal imaging equipment and the like, produce their full effect.
[0019] In a further highly advantageous embodiment of the invention, securing devices are attached at least to what, in the assembled state of the subframe, are the lower external or upper internal bearing points, that interact with eye-like apertures made in the net or in the fabric or tarpaulin. It is possible here to secure the camouflage net, or the fabric or tarpaulin, very quickly to the appropriate bearing points of the subframe. As a result of this very simple and effective securing option, the camouflage net, or the tarpaulin or fabric, can be secured comparatively quickly and simply, so that the assembly of an appropriate camouflage shelter in adverse conditions, such as night, mist, heavy precipitation, high wind or the like, also becomes relatively straightforward.
[0020] In principle, such securing devices are possible at all points, but they are particularly useful at the lower external bearing points and the upper internal bearing points when the subframe is assembled and used as intended. Securing the camouflage net or the tarpaulin or fabric at these bearing points enables it to be stretched. Thus, particularly advantageously, very rapid and nevertheless secure assembly can be achieved with only a few of these securing devices.
[0021] A further advantage lies in the fact that only a few of the comparatively costly and complex bearing points with the securing devices are required for each subframe.
[0022] In a further very favorable development of the invention, the securing device consists of a twist knob, provided with a threaded element, and a bearing element, the twist knob having a larger diameter than each of the eye-like apertures made in the camouflage net, or in the fabric or tarpaulin, and the threaded element having a smaller diameter than each of these apertures.
[0023] As a result of this very simple assembly, advantageously a reliable and very rapid securing of the net or fabric is achieved by clamping it between the twist knob and the bearing surface, at the respective bearing point of the subframe, which can be simply and reliably implemented even under adverse circumstances.
[0024] All these camouflage shelters described also offer the advantage of very light weight, high stability and very rapid assembly or dismantling of the camouflage shelter in question with a comparatively small deployment of operating personnel.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] Further advantageous embodiments of the invention are apparent from the other dependent claims and from the example of embodiment described below with reference to the drawing, in which:
[0026] [0026]FIG. 1 shows a front view of a camouflage shelter according to the invention;
[0027] [0027]FIG. 2 shows a plan view of part of the camouflage shelter according to the invention;
[0028] [0028]FIG. 3 shows a side view of part of the camouflage shelter according to the invention; and
[0029] [0029]FIGS. 4 and 4 a shows a possible method of securing the camouflage net at one of the bearing points.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0030] In FIG. 1, a camouflage shelter 1 can be seen, which is designed to camouflage mobile military hardware, indicated here by the box 2 drawn in dot-and-dash lines. The hardware 2 to be camouflaged may be, preferably, tactical vehicles, weapons systems or the like, but the camouflage shelter 1 can also be used to camouflage individuals, central stores depots or the like. The camouflage shelter 1 is here assembled from a subframe 3 , which is designed as a collapsible selfsupporting lattice of poles 4 . The poles 4 are combined at their ends to form respective groups extending radially to external end points 5 and internal end points 6 or bearing points. The poles 4 are pivotably assembled at these end or bearing points 5 , 6 . In between, they form scissor-like pairs, which are likewise pivotably connected to one another at their intersections 7 . Such a subframe 3 , known per se, can be assembled and dismantled very simply, this assembly or dismantling taking place very quickly and requiring only a minor deployment of personnel.
[0031] A camouflage net 8 is then laid over the outer end points 5 , which in the example of embodiment shown here define a roughly semicircular outline. This camouflage net 8 can then be secured in a customary and conventional manner with ground pegs or the like in an area of ground 9 at the lower end of the camouflage shelter 1 .
[0032] As a result of the fact that, because of the subframe 3 , at least the very great majority of each of the articles of hardware 2 to be camouflaged must remain within the area defined by the inner bearing points 6 , unobstructed convective heat exchange can take place between the area below the camouflage net 8 and the environment. When the camouflage net 8 is used as a polyester mesh with a perforated structure and the appropriate incorporated metallic and nonmetallic absorbent materials, this ensures that the objects 2 located under the camouflage shelter 1 remain concealed from thermal imaging equipment and radar or microwave detection equipment.
[0033] In addition to the assembly of the subframe 3 and the camouflage net 8 , a tarpaulin 10 is here indicated in dotted lines at the inner bearing points 6 . Owing to the assembly of the subframe 3 already described, with the inner and outer bearing points 5 , 6 occurring in pairs, an intermediate space 11 thus arises between the tarpaulin 10 , which protects the hardware 2 to be camouflaged against the influence of weather, precipitation or the like, in which intervening space 11 unobstructed heat convection can take place, as a result of which the satisfactory functioning of the camouflage net 8 is also made possible in conjunction with the tarpaulin 10 . Both the intermediate space 11 and the distance between the individual poles 4 are so large here that the camouflage net 8 is only occasionally in contact and thus the effectiveness and protection against detection with thermal imaging equipment or the like are achieved as a result of the fact that convection can take place between the outside and the inside.
[0034] [0034]FIG. 2 and FIG. 3 each show only one area, which may represent both a complete camouflage shelter 1 and a subarea of a corresponding, larger camouflage shelter 1 . The two figures have been drawn without a camouflage net 8 or tarpaulin 10 in order to make the assembly of the subframe 3 of the camouflage shelter 1 more clearly identifiable.
[0035] In FIG. 4, a securing device 12 can be seen at one of the outer bearing points 5 , as arranged in at least the lower region of the subframe 3 . In the case of the inner bearing points 6 (not shown), of course, the corresponding upper area, or an arrangement at virtually all bearing points, would be logical.
[0036] I n addition, FIGS. 4 and 4 a shows a part of the camouflage net 8 which has an aperture 13 in the area of this securing device 12 , this aperture 13 being surrounded by an eye 14 . The aperture 13 , or the eye 14 , is matched in its diameter to the securing device 12 . The camouflage net 8 is again shown in a dot-and-dash representation, mounted on the securing device 12 .
[0037] In this case, an inner side 16 of the eye 14 comes to rest on a supporting element 15 and a previously removed twist knob 17 of the securing device 12 is subsequently reconnected to the supporting element 15 via a threaded element 18 . The camouflage net 8 is clamped by the area of its aperture 13 or eye 14 between the twist knob 17 and the supporting element 15 . A very reliable securing of the camouflage net 8 on the subframe 3 of the camouflage shelter 1 can thereby be achieved. This securing causes no problems and is simple to carry out even in adverse conditions, such as, for example, wind, mist, precipitation, darkness or the like, and additionally guarantees reliable securing of the camouflage net 8 on the subframe 3 .
[0038] This type of securing is, of course, also possible in the case of the inner bearing points 6 , and tarpaulin 10 . As a result of an appropriate design of the eye 14 , especially of its diameter or of an appropriate coating with a sealant material, waterproofing of the tarpaulin 10 of the camouflage shelter 1 can be achieved here without problems. | A camouflage shelter ( 1 ) has a collapsible self-supporting subframe ( 3 ), which is assembled from a lattice of poles ( 4 ), which are coupled in an articulated manner at their ends and form scissor-like pairs. The poles ( 4 ) are rotatably connected at their intersections ( 7 ). The camouflage shelter ( 1 ) has a camouflage net ( 8 ) arranged loosely over outer bearing points ( 5 ) of the subframe ( 3 ) and consisting of a polyester mesh with a perforated structure, incorporated metal fibers and a coating which contains absorbent pigments. | 5 |
BACKGROUND OF THE INVENTION
[0001] Inhibitors of 11β-Hydroxysteroid Dehydrogenase Type 1 (11β-HSD1) are promising drugs for the treatment of a number of diseases and disorders as described in detail in U.S. Provisional Patent Application No. 60/962,058, filed Jul. 26, 2007; U.S. Provisional Patent Application No. 61/001,253, filed Oct. 31, 2007; U.S. Provisional Patent Application No. 61/049,650, filed May 1, 2008; and International Application No. PCT/US2008/009017 all of which are herein incorporated by reference in their entirety.
[0002] For example, 11β-HSD1 inhibitors are promising for the treatment of diabetes, metabolic syndrome, obesity, glucose intolerance, insulin resistance, hyperglycemia, hypertension, hypertension-related cardiovascular disorders, hyperlipidemia, deleterious gluco-corticoid effects on neuronal function (e.g. cognitive impairment, dementia, and/or depression), elevated intra-ocular pressure, various forms of bone disease (e.g., osteoporosis), tuberculosis, leprosy (Hansen's disease), psoriasis, and impaired wound healing (e.g., in patients that exhibit impaired glucose tolerance and/or type 2 diabetes).
[0003] There is a need for better, for example, more economical and more efficient methods for synthesis of the 11β-HSD1 inhibitors.
SUMMARY OF THE INVENTION
[0004] The present invention provides economical and efficient methods for the synthesis of 11β-HSD1 inhibitors, for example, oxazinone compounds and tertiary alcohol oxazinone compounds as disclosed herein.
[0005] One embodiment of the present invention is a method of preparing an oxazinone compound represented by structural formula (I):
[0000]
[0006] R 1 is (a) absent or (b) is selected from optionally substituted (C 1 -C 6 )alkyl, optionally substituted (C 2 -C 6 )alkenyl, optionally substituted (C 2 -C 6 )alkynyl, optionally substituted (C 1 -C 3 )alkoxy(C 1 -C 3 )alkoxy, and optionally substituted (C 1 -C 3 )alkoxy(C 1 -C 3 )alkyl;
[0007] E is (a) a bond or (b) (C 1 -C 3 )alkylene or (C 1 -C 2 )alkoxy, wherein the O is attached to R 2 , each of which is optionally substituted with 1 to 4 groups independently selected from methyl, ethyl, trifluoromethyl and oxo;
[0008] R 2 is selected from optionally substituted (C 1 -C 6 )alkyl, optionally substituted aryl, optionally substituted heteroaryl, optionally substituted cycloalkyl or optionally substituted heterocyclyl;
[0009] R 3 is selected from optionally substituted (C 1 -C 6 )alkyl, optionally substituted (C 2 -C 6 )alkenyl, optionally substituted (C 2 -C 6 )alkynyl, optionally substituted (C 3 -C 5 )cycloalkyl(C 1 -C 4 )alkyl, optionally substituted (C 1 -C 3 )alkoxy(C 1 -C 3 )alkoxy and optionally substituted (C 1 -C 3 )alkoxy(C 1 -C 3 )alkyl;
[0010] A 1 is (a) a bond, or (b) (C 1 -C 3 )alkylene, CH 2 CH 2 O, wherein the oxygen is attached to Cy 1 ;
[0011] Cy 1 is optionally substituted aryl, optionally substituted heteroaryl, optionally substituted monocyclic cycloalkyl or optionally substituted monocyclic heterocyclyl;
[0012] A 2 is (a) a bond, O, S or NR 4 , wherein R 4 is (C 1 -C 3 )alkyl or (C 3 -C 6 )cycloalkyl; or (b) (C 1 -C 3 )alkylene or (C 1 -C 2 )alkoxy, each of which is optionally substituted with 1 to 4 groups independently selected from methyl, ethyl, or trifluoromethyl.
[0013] Cy 2 is (a) hydrogen or (b) optionally substituted aryl, optionally substituted heteroaryl, optionally substituted cycloalkyl or optionally substituted heterocyclyl.
[0014] The method comprises the step of reacting a β-haolalcohol compound, for example a β-haloalcohol compound represented by structural formula (II)
[0000]
[0000] with an isocyanate compound represented by structural formula (III)
[0000]
[0000] X is a leaving group
[0015] Another embodiment of the present invention is a method of preparing an epoxide compound represented by structural formula (IV):
[0000]
[0016] The method comprises the step of oxidizing with an epoxidation reagent a 2-methyl-3-propenyl intermediate represented by the following structural formula:
[0000]
[0000] A 1 , A 2 , Cy 1 , Cy 2 , R 1 , R 2 and E in structural formulas (IV) and (V) are as defined in structural formula (I).
[0017] Another embodiment of the present invention is a method of preparing tertiary alcohol oxazinone compound represented by structural formula (VI):
[0000]
[0000] The method comprises the step of reducing the epoxide group of the epoxide compound represented by structural formula (IV) with a reducing agent. A 1 , A 2 , Cy 1 , Cy 2 , R 1 , R 2 and E in structural formula (VI) are as defined in structural formula (V).
[0018] In an alternative embodiment, the tertiary alcohol oxazinone compound represented by structural formula (VI) can be prepared using the compound of structural formula VII:
[0000]
[0000] following the synthetic scheme set forth in FIG. 2 . Example 22 provides details of the synthetic steps of FIG. 2 for the preparation of (S)-3-((S)-1-(4-bromophenyl) ethyl)-6-(2-hydroxy-2-methylpropyl)-6-phenyl-1,3-oxazinan-2-one.
[0019] A 1 , A 2 , Cy 1 , Cy 2 , R 1 , R 2 and E in structural formula (VII) are as defined in structural formula (I).
[0020] Another embodiment of the present invention is an epoxide compound represented by structural formula (IV) or a salt thereof.
[0021] Yet another embodiment of the present invention is a 2-methyl-3-propenyl intermendiate represented by structural formula (V) or a salt thereof.
[0022] Other embodiments of the present invention are the epoxide compounds and salts thereof, and 2-methyl-3-propenyl intermediates and salts thereof as prepared with the methods of the present invention, in particular, the epoxide compounds and 2-methyl-3-propenyl intermediates corresponding to the above described embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] FIG. 1 is a schematic, showing the synthesis of a specific tertiary alcohol oxazinone compound, a 11β-HSD1 inhibitor, using the methods disclosed herein.
[0024] FIG. 2 is a schematic, showing the synthesis of a specific tertiary alcohol oxazinone compound, a 11β-HSD1 inhibitor, using the methods disclosed herein.
DETAILED DESCRIPTION OF THE INVENTION
[0025] The present invention provides methods for synthesizing 11β-HSD1 inhibitors, for example, oxazinone compounds and tertiary alcohol oxazinone compounds as disclosed herein.
[0026] The oxazinone compound represented by structural formula (I), for example, compounds 5 and 6 (see Figure), can be prepared by reacting a β-haloalcohol compound represented by structural formula (II) with an isocyanate compound represented by structural formula (III). Both, the β-haloalcohol compound and the isocyanate compound can be prepared from commercially available compounds using methods known in the art (see, Exemplification section).
[0027] The tertiary alcohol oxazinone compound represented by structural formula (VI) such as, for example, compound 8 (see FIG. 1 ) is prepared by first oxidizing 2-methyl-3-propenyl intermediate represented by structural formula (V) with an epoxidation reagent to obtain the epoxide compound represented by structural formula (IV). The 2-methyl-3-propenyl intermediate is an oxazinone compound that can be prepared using the method described in the previous paragraph, wherein R 3 is 2-methyl-3-propenyl. In a second step, the epoxide group of the epoxide compound is reduced with a reducing agent to form the tertiary alcohol oxazinone compound.
[0028] Oxazinone compounds and tertiary alcohol oxazinone compounds represented by structural formulas (I) and (VI), respectively, for which Cy 1 is phenyl substituted with a leaving group (e.g., —Br) and optionally substituted with one or more additional substituents, can be used to prepare biaryl group containing 11β-HSD1 inhibitors, for example, by using a “Suzuki” coupling reaction as described in Example 111 of U.S. Provisional Patent Application No. 60/962,058, filed Jul. 26, 2007. Alternatively, oxazinone compounds represented by structural formulas (I) and (VI), respectively, for which Cy 1 is phenyl substituted with a leaving group (e.g., —Br) and optionally substituted with one or more additional substituents, can be used to prepare biaryl group containing 11β-HSD1 inhibitors, by conversion of the leaving group (e.g. —Br) to a boronic acid or boronate ester, followed by using a “Suzuki” coupling reaction with Cy 2 -Cl or Cy 2 -Br (see EXAMPLE 23). Alternatively, biaryl group containing 11β-HSD1 inhibitors can be obtained from isocyanate compounds that already contain the biaryl group using the methods of the present invention. The synthesis of a variety of biaryl compounds is provided in the Exemplification section.
[0029] A detailed description of each reaction in the syntheses is provided below. In the discussion below, A 1 , A 2 , Cy 1 , Cy 2 , R 1 , R 2 and E have the meanings indicated above unless otherwise noted. In cases where the synthetic intermediates and final products described below contain potentially reactive functional groups, for example amino, hydroxyl, thiol, sulfonamide, amide and carboxylic acid groups, that may interfere with the desired reaction, it may be advantageous to employ protected forms of the intermediate. Methods for the selection, introduction and subsequent removal of protecting groups are well known to those skilled in the art. (T. W. Greene and P. G. M. Wuts “Protective Groups in Organic Synthesis” John Wiley & Sons, Inc., New York 2007, herein incorporated by reference in its entirety). Such protecting group manipulations are assumed in the discussion below and not described explicitly. The term “protected” as used herein in combination with terms denoting chemical groups, for example, protected piperidinyl, refers to the chemical group with its functional groups that may interfere with a desired reaction having been reacted with a protective group, e.g., the ring nitrogen atom in the case piperidine.
Oxazinone Compounds
[0030] The oxazinone compound represented by structural formula (I) is prepared by reacting a β-haloalcohol compound represented by structural formula (II) with an isocyanate compound represented by structural formula (III) as shown above. Typically, the reaction of the a β-haloalcohol with the isocyanate compound is carried out in the presence of a base. More typically, the reaction is carried out in the presence of a non-nucleophilic base. Most typically, the reaction is carried out in the presence of a non-nucleophilic amine base. Suitable non-nucleophilic amide bases include, but are not limited to as lithium amide (LiNH 2 ), sodium amide (NaNH 2 ), lithium dimethylamide, lithium diethylamide, lithium diisopropylamide, lithium dicyclohexylamide, silicon-based amides, such as sodium and potassium bis(trimethylsilyl)amide, lithium tetramethylpiperidide, and lithium tetramethylpiperidine. Other non-nucleophilic bases include but are not limited to sodium hydride, sodium tert-pentoxide and sodium tert-butoxide. Examples of suitable non-nucleophilic amine bases include, but are not limited to, diisopropylethylamine, 2,2,6,6-tetramethylpiperidine, 4-dimethylaminopyridine, 2,6-di-tert-butyl-4-methylpyridine, 1,5-diazabicyclo[4.3.0]non-5-ene (DBN), 1,4-diazabicyclo[2.2.2]octane (DABCO), 1,8-diazabicyclo[5.4.0]undec-7-ene (DBU), 2,8,9-trimethyl-2,5,8,9-tetraaza-l-phosphabicyclo[3.3.3]undecane and the like. Most typically, the base is 1,8-diazabicyclo[5.4.0]undec-7-ene. Although an excess of either β-haloalcohol compound or isocyanate compound can be used, the isocyanate compound is more commonly used in excess. Typically, from about one to about ten equivalents of base relative to β-haloalcohol are used, more typically from about one to about six equivalents, and, even more typically, from one to about 5 equivalents. Typically the reaction is carried out in an anhydrous aprotic, non-nucleophilic solvent at β-haloalcohol compound concentrations between about 0.01 M and 5 M. β-Haloalcohol compound concentrations are more typically, however, between about 0.05 M and 2 M. Suitable solvents include, but are not limited to ethereal solvents such as diethyl ether, tetrahydrofuran (THF), tert-butyl-methyl ether and 1,4-dioxane, and non-ethereal solvents such as dimethyl formamide and dimethyl sulfoxide and the like. Suitable reaction temperatures generally range from about 0° C. to about the boiling point of the solvent. More typically, temperatures are sufficiently high to allow refluxing, for example, about 68° C. for tetrahydrofuran.
Epoxide Compounds
[0031] The epoxide compound represented by structural formula (IV) is prepared by oxidizing the propenyl group of the 2-methyl-3-propenyl intermediate represented by structural formula (V) with an epoxidation reagent. The 2-methyl-3-propenyl intermediate is an oxazinone compound that can be prepared using the method described in the previous paragraphs (e.g., the reaction of a compound of Formula II with a compound of Formula III). Suitable epoxidation reagents include, but are not limited to peroxides (e.g., hydrogen peroxide, t-butyl hydroperoxide), peroxycarboxylic acids (e.g., 3-chloroperbenzoic acid (MCPBA), peracetic acid, pertrifluoroacetic acid), magnesium bis(monoperoxyphthalate) hexahydrate, potassium monoperoxysulfate optionally in the presence of 1,2:4,5-di-O-isopropylidene-β-D-erythro-2,3-hexodiulo-2,6-pyranose, dimethyldioxirane and the like. Typically, the epoxidation reagent is a peroxycarboxylic acid, and, most typically, it is 3-chloroperbenzoic acid. Typically, from about one to about ten equivalents of epoxidation reagent relative to 2-methyl-3-propenyl intermediate are used, more typically from about one to about six equivalents, and, most typically, from about one to about 2 equivalents. Typically the reaction is carried out in an aprotic, non-nucleophilic solvent at 2-methyl-3-propenyl intermediate concentrations between about 0.01 M and 5 M. 2-Methyl-3-propenyl intermediate concentrations are more typically, however, between about 0.05 M and 2 M. Suitable solvents include, but are not limited to, halogenated solvents (e.g., chloroform, dichloromethane and 1,2-dichloroethane, acetonitrile, dimethylformamide (DMF), dimethylacetamide (DMA), or hexamethylphosphorus triamide and ethereal solvents such as diethyl ether, tetrahydrofuran (THF) and 1,4-dioxane. Typically, the solvent is a halogenated solvent. More typically, the solvent is dichloromethane or 1,2-dichloroethane. Most typically, the solvent is dichloromethane. Suitable reaction temperatures generally range from about 0° C. to about the boiling point of the solvent used. Most typically, the reaction is carried out at ambient temperature.
Tertiary Alcohol Oxazinone Compounds
[0032] The tertiary alcohol oxazinone compound represented by structural formula (VI) is prepared by reducing the epoxide group of the epoxide compound represented by structural formula (IV) with a reducing agent. Suitable reducing agents include, but are not limited to hydride reducing agents such as lithium triethylborohydride, LiAlH 4 , LiBH 4 , lithium tri-t-butoxyaluminum hydride in the presence of triethylborane, potassium tri-sec-butylborohydride or sodium bis(2-methoxyethoxy)aluminum hydride and the like. Other suitable reducing agents include, but are not limited to BH 3 .Et 3 N—LiClO 4 , lithium di-tert-butylbiphenyl, or hydrogen or sodium formate in the presence of palladium on charcoal. Most typically, the reducing agent is lithium triethylborohydride (super hydride). Typically, from about one to about ten equivalents of reducing agent relative to the epoxide compound are used, more typically from about one to about six equivalents, and, most typically, from about one to about 2 equivalents. Typically the reaction is carried out in an anhydrous aprotic, non-nucleophilic solvent at epoxide compound concentrations between about 0.01 M and 5 M. Epoxide compound concentrations are more typically, however, between about 0.05 M and 2 M. Suitable solvents include, but are not limited to ethereal solvents such as diethyl ether, tetrahydrofuran (THF), tert-butyl-methyl ether and 1,4-dioxane, and non-ethereal solvents such as dimethyl formamide and dimethyl sulfoxide and the like. Typically, the solvent is an ethereal solvent. Most typically, the solvent is anhydrous tetrahydrofuran. Suitable reaction temperatures generally range from about 0° C. to about ambient temperature.
[0033] The processes for preparing the oxazinone compound represented by structural formula (I), the epoxide compound represented by structural formula (IV) and the tertiary alcohol oxazinone compound represented by structural formula (VI) as described in the previous three paragraphs and for the compounds represented by structural formulas (I), (IV), (V), (VI) and (VII) can further be described according to the following preferred embodiments. Note that R 3 and X refer to the preparation of an oxazinone compound only.
[0034] In a first preferred embodiment, Cy 1 , Cy 2 , R 2 , R 3 and X are as defined in structural formulas (I) to (VI) (see summary of invention) and R 1 is absent or is (C 1 -C 6 )alkyl; A 1 is a bond, CH 2 , or CH 2 CH 2 , or CH when R 1 is present; A 2 is a bond, O, OCH 2 CO or CH 2 ; X is a Cl, Br, I or —OSO 2 R, wherein R is (C 1 -C 4 )alkyl optionally substituted with one or more F, or phenyl optionally substituted with halogen, (C 1 -C 4 )alkyl or NO 2 ; and E is a bond or (C 1 -C 3 )alkylene.
[0035] In a second preferred embodiment, R 1 , R 2 , R 3 , X and E are as defined in the first preferred embodiment and A 1 is a bond or CH when R 1 is present; A 2 is a bond; Cy is hydrogen; Cy 1 is phenyl substituted with Cl, Br, I or OSO 2 CF 3 , and optionally substituted with one or more additional substituents.
[0036] In a third preferred embodiment, A 2 , Cy 2 , R 1 , R 2 , R 3 , X and E are as defined in the second preferred embodiment and A 1 is —CH, R 1 is present and Cy 1 is represented by the following structural formula:
[0000]
[0037] Z is a Cl, Br, I, OSO 2 CF 3 , OSO 2 Me, or OSO 2 C 6 H 4 Me, r is 0, 1, 2 or 3; and each G 1 is independently selected from the group consisting of (C 1 -C 4 )alkyl, halo(C 1 -C 4 ) alkyl, (C 11 -C 4 )alkoxy, halogen, cyano and nitro.
[0038] In a fourth preferred embodiment, A 1 , A 2 , Cy 1 , Cy 2 , R 2 , R 3 , X, E, r, G 1 and Z are defined as in the third preferred embodiment and R 1 is methyl or ethyl.
[0039] In a fifth preferred embodiment, A 1 , A 2 , Cy 1 , C 2 , R 1 , X, E, r, G 1 and Z are defined as in the fourth preferred embodiment and R 2 is phenyl, thienyl, or pyridyl, each optionally substituted with halogen, nitro, cyano, (C 1 -C 6 )alkyl, protected hydroxy(C 1 -C 3 )alkyl, (C 1 -C 3 )alkoxy, protected CONH 2 , protected carboxylic acid and SO 2 Me; and with regard to the preparation of an oxazinone compound, R 3 is methyl, ethyl, propyl, butyl, vinyl, allyl, 2-methyl-3-propenyl, or ethoxyethyl, each optionally substituted with up to two groups independently selected from (C 1 -C 4 )alkyl, (C 1 -C 4 )alkoxy, (C 1 -C 4 )alkoxycarbonyl, benzyloxycarbonyl, protected hydroxy(C 1 -C 4 )alkyl, cyano(C 1 -C 4 )alkyl, protected (C 1 -C 4 )alkylamino, di(C 1 -C 4 )alkylamino, halogen, cyano, oxo, nitro, protected hydroxy, protected amino, MeSO 2 —, MeSO 2 N(Me)(C 1 -C 4 )alkyl, protected MeSO 2 NH(C 1 -C 4 )alkyl, protected H 2 NC(═O)CMe 2 (C 1 -C 4 )alkyl, protected H 2 NC(═O)CHMe(C 1 -C 4 )alkyl and protected H 2 NC(═O)CH 2 (C 1 -C 4 )alkyl.
[0040] In a sixth preferred embodiment, A 1 , A 2 , Cy 1 , Cy 2 , R 1 , R 2 , X, E, r, G 1 and Z are defined as in the fifth preferred embodiment and, with regard to the preparation of an oxazinone compound, R 3 is vinyl, allyl, 2-methyl-3-propenyl, MeSO 2 NHCH 2 CH 2 CH 2 , protected H 2 NC(═O)CH 2 CH 2 , protected H 2 NC(═O)CMe 2 CH 2 , 2-cyano-2-methylpropyl, 2-oxopropyl or (C 1 -C 4 )alkoxycarbonylmethyl.
[0041] In a seventh preferred embodiment, A 1 , A 2 , Cy 1 , Cy 2 , R 1 , R 3 , X, E, r, G 1 and Z are defined as in the sixths preferred embodiment and R 2 is phenyl optionally substituted with 1, 2 or 3 substituents selected from halo, cyano, protected CONH 2 , (C 1 -C 4 )alkyl, (C 1 -C 4 )alkoxy and SO 2 Me.
[0042] In an eight preferred embodiment, A 1 , A 2 , Cy 1 , Cy 2 , R 1 , R 2 , X, E, r, G 1 and Z are defined as in the seventh preferred embodiment and, with regard to the preparation of an oxazinone compound, R 3 is allyl, 2-methyl-3-propenyl, protected H 2 NC(═O)CMe 2 CH 2 or 2-cyano-2-methylpropyl.
[0043] In a ninth preferred embodiment, A 1 , A 2 , Cy 1 , Cy 2 , R 1 , R 2 , X, E, r, G 1 and Z are defined as in the seventh preferred embodiment and, with regard to the preparation of an oxazinone compound, R 3 is 2-methyl-3-propenyl or 2-cyano-2-methylpropyl.
[0044] In a tenth preferred embodiment, A 1 , A 2 , Cy 1 , Cy 2 , R 1 , R 3 , X, E, r, G 1 and Z are defined as in the ninth preferred embodiment and R 2 is phenyl or fluorophenyl.
[0045] In an eleventh preferred embodiment, A 1 , A 2 , R 1 , R 2 , R 3 , X and E are defined as in the first preferred embodiment and Cy 1 is phenyl, cyclopropyl, cyclohexyl, pyrrolidinyl, piperidinyl, azepanyl, pyridyl, thiazolyl, pyrimidinyl, each optionally substituted with 1 to 4 groups; and Cy 2 is phenyl, thienyl, pyridyl, cyclopropyl, piperidinyl, piperazinyl, morpholinyl, thiazolyl, oxadiazolyl, thiadiazolyl, pyrazolyl, S,S-dioxothiazinyl, pyridazinyl, pyrimidinyl, pyrazinyl, benzimidazolyl, benztriazolyl, oxodihydropyridyl, oxodihydropyridazinyl, oxodihydropyrimidinyl and oxodihydropyrazinyl, each optionally substituted by 1 to 4 groups; wherein substituents for a ring carbon atom of Cy 1 and Cy 2 are independently selected from halogen, cyano, oxo, nitro, protected hydroxy, protected amino, (C 1 -C 4 )alkyl, (C 3 -C 4 )cycloalkyl, (C 3 -C 4 )cycloalkyl(C 1 -C 2 )alkyl, (C 1 -C 4 )alkoxy, (C 11 -C 4 )alkoxycarbonyl, benzoxycarbonyl, protected CONH 2 , protected (C 1 -C 4 )alkylaminocarbonyl, di(C 1 -C 4 )alkylaminocarbonyl, protected (C 3 -C 4 )cycloalkylaminocarbonyl, {(C 1 -C 4 )alkyl} {(C 3 -C 4 )cycloalkyl} aminocarbonyl and protected (C 1 -C 4 )alkylcarbonylamino, wherein suitable substituents for a substitutable ring nitrogen atom in Cy 2 are selected from the group consisting of (C 1 -C 4 )alkyl, (C 3 -C 4 )cycloalkyl, (C 3 -C 4 )cycloalkyl(C 1 -C 2 )alkyl, (C 1 -C 4 )alkoxycarbonyl, (C 1 -C 4 )alkylcarbonyl and benzyloxycarbonyl. For the process of preparing an oxazinone compound, each substitutable ring nitrogen atom of Cy 2 , if present, is either bonded to A 2 , protected or substituted.
[0046] In a twelfth preferred embodiment, A 1 , A 2 , Cy 1 , Cy 2 , R 2 , R 3 , X and E are defined as in the eleventh preferred embodiment and R 1 is methyl or ethyl.
[0047] In a thirteenth preferred embodiment, A 1 , A 2 , Cy 1 , Cy 2 , R 1 , X and E are defined as in the twelfth preferred embodiment and R 2 is phenyl, thienyl, or pyridyl, each optionally substituted with halogen, nitro, cyano, (C 1 -C 6 )alkyl, protected hydroxy(C 1 -C 3 )alkyl, (C 1 -C 3 )alkoxy, protected CONH 2 , protected carboxylic acid and SO 2 Me; and, with regard to the preparation of an oxazinone compound, R 3 is methyl, ethyl, propyl, butyl, vinyl, allyl, 2-methyl-3-propenyl, or ethoxyethyl each optionally substituted with up to two groups independently selected from (C 1 -C 4 )alkyl, (C 1 -C 4 )alkoxy, (C 1 -C 4 )alkoxycarbonyl, benzyloxycarbonyl, protected hydroxy(C 1 -C 4 )alkyl, cyano(C 1 -C 4 )alkyl, protected (C 1 -C 4 )alkylamino, di(C 1 -C 4 )alkylamino, halogen, cyano, oxo, nitro, protected hydroxy, protected amino, MeSO 2 —, MeSO 2 N(Me)(C 1 -C 4 )alkyl, protected MeSO 2 NH(C 1 -C 4 )alkyl, protected H 2 NC(═O)CMe 2 (C 1 -C 4 )alkyl, protected H 2 NC(═O)CHMe(C 1 -C 4 )alkyl and protected H 2 NC(═O)CH 2 (C 1 -C 4 )alkyl.
[0048] In a fourteenth preferred embodiment, A 1 , A 2 , Cy 1 , R 1 , R 2 , R 3 , X and E are defined as in the thirteenth preferred embodiment and Cy 2 is optionally substituted and selected from the group consisting of benzimidazolyl, benzotriazolyl, oxodihydropyridyl, oxodihydropyridazinyl, oxodihydropyrimidinyl, oxodihydropyrazinyl, piperidinyl, pyridinyl, pyridazinyl, pyrimidinyl, pyrazinyl, pyrazolyl, thiazolyl and thiadiazolyl.
[0049] In a fifteenth preferred embodiment, A 1 , A 2 , Cy 1 , Cy 2 , R 1 , R 2 , X and E are defined as in the fourteenth preferred embodiment and, with regard to the preparation of an oxazinone compound, R 3 is vinyl, allyl, 3-propenyl-2-methyl, MeSO 2 NHCH 2 CH 2 CH 2 , protected H 2 NC(═O)CH 2 CH 2 , protected H 2 NC(═O)CMe 2 CH 2 , 2-cyano-2-methylpropyl, 2-oxopropyl or (C 1 -C 4 )alkoxycarbonylmethyl.
[0050] In a sixteenth preferred embodiment, A 1 , A 2 , Cy 1 , Cy 2 , R 1 , R 3 , X and E are defined as in the fifteenth preferred embodiment and R 2 is phenyl optionally substituted with 1, 2 or 3 substituents selected from halo, cyano, protected CONH 2 , (C 1 -C 4 )alkyl, (C 1 -C 4 )alkoxy and SO 2 Me.
[0051] In a seventeenth preferred embodiment, A 1 , A 2 , Cy 1 , Cy 2 , R 1 , R 2 , X and E are defined as in the sixteenth preferred embodiment and with regard to the preparation of an oxazinone compound, R 3 is allyl, 3-propenyl-2-methyl, protected H 2 NC(═O)CMe 2 CH 2 or 2-cyano-2-methylpropyl.
[0052] In an eighteenth preferred embodiment, A 1 , A 2 , Cy 1 , Cy 2 , R 1 , R 2 , X and E are defined as in the seventeenth preferred embodiment and, with regard to the preparation of an oxazinone compound, R 3 is 3-propenyl-2-methyl, or 2-cyano-2-methylpropyl.
[0053] In a nineteenth preferred embodiment, A 1 , A 2 , Cy 1 , C 2 , R 1 , R 3 , X and E are defined as in the eighteenth preferred embodiment and R 2 is phenyl or fluorophenyl.
[0054] In a twentieth preferred embodiment, A 1 , A 2 , Cy 1 , Cy 2 , R 1 , R 2 , R 3 , X and E are defined as in the nineteenth preferred embodiment and suitable substituents for a substitutable ring nitrogen atom in the group represented by Cy 2 are selected from the group consisting of (C 1 -C 4 )alkyl, (C 3 -C 4 )cycloalkyl, (C 3 -C 4 )cycloalkyl(C 1 -C 2 )alkyl, (C 1 -C 4 )alkoxycarbonyl and (C 1 -C 4 )alkylcarbonyl; and suitable substituents for a substitutable ring carbon atom in the Cy 2 is selected from the group consisting fluorine, chlorine, cyano, protected hydroxy, protected amino, (C 1 -C 4 )alkyl, (C 3 -C 4 )cycloalkyl, (C 3 -C 4 )cycloalkyl(C 1 -C 2 )alkyl, (C 1 -C 4 )alkoxy, protected CONH 2 , protected (C 1 -C 4 )alkylaminocarbonyl, di(C 1 -C 4 )alkylaminocarbonyl, protected (C 3 -C 4 )cycloalkylaminocarbonyl, {(C 1 -C 4 )alkyl} {(C 3 -C 4 )cycloalkyl} aminocarbonyl and protected (C 1 -C 4 )alkylcarbonylamino.
[0055] In a twenty-first preferred embodiment, with regard to the preparation of an oxazinone compound, A 1 , A 2 , Cy 1 , Cy 2 , R 1 , R 2 , X and E are as defined in any one of the above preferred embodiments and R 3 is 2-methyl-3-propenyl.
[0056] In a twenty-second preferred embodiment, with regard to the preparation of an oxazinone compound, A 1 , A 2 , Cy 1 , Cy 2 , R 1 , R 2 , X and E are as defined in any one of the above preferred embodiments and R 3 is 3-propenyl.
[0057] In a twenty-third preferred embodiment, A 1 , A 2 , Cy 1 , R 1 , R 2 , X and E are as defined in any one of the above preferred embodiments and Cy 2 is represented by one of the following structural formulas:
[0000]
[0058] G 2a is (C 1 -C 4 )alkyl, (C 3 -C 4 )cycloalkyl or (C 1 -C 4 )haloalkyl; G 2b is hydrogen, fluorine, chlorine, cyano, hydroxy, amino, (C 1 -C 4 )alkyl, (C 3 -C 4 )cycloalkyl, (C 3 -C 4 )cycloalkyl(C 1 -C 2 )alkyl, halo(C 1 -C 4 )alkyl, (C 1 -C 4 )alkoxy, (C 1 -C 4 )haloalkoxy, CONH 2 , (C 1 -C 4 )alkylaminocarbonyl, di(C 1 -C 4 )alkylaminocarbonyl or (C 1 -C 4 )alkylcarbonylamino.
[0059] Other embodiments of the present invention are the epoxide compounds and salts thereof, and 2-methyl-3-propenyl intermediates and salts thereof as prepared with the methods of the present invention, in particular, the epoxide compounds and 2-methyl-3-propenyl intermediates corresponding to the above described preferred embodiments.
[0060] The following individual compounds can be prepared by a suitable choice of starting materials:
[0061] (S)-3-((S)-1-(4-(1,5-dimethyl-6-oxo-1,6-dihydropyridazin-3-yl)phenyl)ethyl)-6-(2-hydroxy-2-methylpropyl)-6-phenyl-1,3-oxazinan-2-one
[0062] (S)-3-((S)-1-(4-(1,4-dimethyl-6-oxo-1,6-dihydropyridazin-3-yl)phenyl)ethyl)-6-(2-hydroxy-2-methylpropyl)-6-phenyl-1,3-oxazinan-2-one
[0063] (S)-3-((S)-1-(4-(1,2-dimethyl-1H-benzo[d]imidazol-6-yl)phenyl)ethyl)-6-(2-hydroxy-2-methylpropyl)-6-phenyl-1,3-oxazinan-2-one
[0064] (S)-6-(2-hydroxy-2-methylpropyl)-3-((S)-1-(4-(1-methyl-1H-benzo [d]imidazol-5-yl)phenyl)ethyl)-6-phenyl-1,3-oxazinan-2-one
[0065] (S)-3-((S)-1-(4-(1,2-dimethyl-1H-benzo[d]imidazol-5-yl)phenyl)ethyl)-6-(2-hydroxy-2-methylpropyl)-6-phenyl-1,3-oxazinan-2-one
[0066] (S)-3-((S)-1-(4-(1-(cyclopropylmethyl)-6-oxo-1,6-dihydropyridazin-3-yl)phenyl)ethyl)-6-(2-hydroxy-2-methylpropyl)-6-phenyl-1,3-oxazinan-2-one
[0067] (S)-3-((S)-1-(4-(1-cyclopropyl-6-oxo-1,6-dihydropyridazin-3-yl)phenyl)ethyl)-6-(2-hydroxy-2-methylpropyl)-6-phenyl-1,3-oxazinan-2-one
[0068] (S)-3-((S)-1-(4-(1-cyclopropyl-2-oxo-1,2-dihydropyridin-4-yl)phenyl)ethyl)-6-(2-hydroxy-2-methylpropyl)-6-phenyl-1,3-oxazinan-2-one
[0069] 2-(4-((S)-1-((S)-6-(2-hydroxy-2-methylpropyl)-2-oxo-6-phenyl-1,3-oxazinan-3-yl)ethyl)phenyl)nicotinonitrile
[0070] (S)-3-((S)-1-(4-(1-(cyclopropylmethyl)-6-oxo-1,6-dihydropyridin-3-yl)phenyl)ethyl)-6-(2-hydroxy-2-methylpropyl)-6-phenyl-1,3-oxazinan-2-one
[0071] N-ethyl-5-(4-((S)-1-((S)-6-(2-hydroxy-2-methylpropyl)-2-oxo-6-phenyl-1,3-oxazinan-3-yl)ethyl)phenyl)picolinamide
[0072] 5-(4-((S)-1-((S)-6-(2-hydroxy-2-methylpropyl)-2-oxo-6-phenyl-1,3-oxazinan-3-yl)ethyl)phenyl)-N-methylpicolinamide
[0073] 5-(4-((S)-1-((S)-6-(2-hydroxy-2-methylpropyl)-2-oxo-6-phenyl-1,3-oxazinan-3-yl)ethyl)phenyl)-N,N-dimethylpicolinamide
[0074] (S)-3-((S)-1-(4-(1H-benzo[d][1,2,3]triazol-6-yl)phenyl)ethyl)-6-(2-hydroxy-2-methylpropyl)-6-phenyl-1,3-oxazinan-2-one
[0075] (S)-6-(2-hydroxy-2-methylpropyl)-3-((S)-1-(4-(2-methyl-1H-benzo[d]imidazol-6-yl)phenyl)ethyl)-6-phenyl-1,3-oxazinan-2-one
[0076] (S)-6-(2-hydroxy-2-methylpropyl)-6-phenyl-3-((S)-1-(4-(1,5,6-trimethyl-2-oxo-1,2-dihydropyridin-4-yl)phenyl)ethyl)-1,3-oxazinan-2-one
[0077] 2-(4-((S)-1-((S)-6-(2-hydroxy-2-methylpropyl)-2-oxo-6-phenyl-1,3-oxazinan-3-yl)ethyl)phenyl)nicotinonitrile
[0078] 2-(4-((S)-1-((S)-6-(2-hydroxy-2-methylpropyl)-2-oxo-6-phenyl-1,3-oxazinan-3-yl)ethyl)phenyl)isonicotinonitrile
[0079] N-tert-butyl-6-(4-((S)-1-((S)-6-(2-hydroxy-2-methylpropyl)-2-oxo-6-phenyl-1,3-oxazinan-3-yl)ethyl)phenyl)nicotinamide
[0080] (S)-3-((S)-1-(4-(2-ethoxy-6-methylpyridin-4-yl)phenyl)ethyl)-6-(2-hydroxy-2-methylpropyl)-6-phenyl-1,3-oxazinan-2-one
[0081] (S)-3-((S)-1-(4-(1-ethyl-6-methyl-2-oxo-1,2-dihydropyridin-4-yl)phenyl)ethyl)-6-(2-hydroxy-2-methylpropyl)-6-phenyl-1,3-oxazinan-2-one
[0082] (S)-3-((S)-1-(4-(6-ethoxy-5-methylpyridin-3-yl)phenyl)ethyl)-6-(2-hydroxy-2-methylpropyl)-6-phenyl-1,3-oxazinan-2-one
[0083] (S)-3-((S)-1-(4-(1-ethyl-5-methyl-6-oxo-1,6-dihydropyridin-3-yl)phenyl)ethyl)-6-(2-hydroxy-2-methylpropyl)-6-phenyl-1,3-oxazinan-2-one
[0084] N-cyclopropyl-6-(4-((S)-1-((S)-6-(2-hydroxy-2-methylpropyl)-2-oxo-6-phenyl-1,3-oxazinan-3-yl)ethyl)phenyl)nicotinamide
[0085] (S)-6-(2-hydroxy-2-methylpropyl)-3-((S)-1-(4-(1-isopropyl-6-oxo-1,6-dihydropyridazin-3-yl)phenyl)ethyl)-6-phenyl-1,3-oxazinan-2-one
[0086] (S)-6-(2-hydroxy-2-methylpropyl)-3-((S)-1-(4-(6-oxo-1-(2,2,2-trifluoroethyl)-1,6-dihydropyridazin-3-yl)phenyl)ethyl)-6-phenyl-1,3-oxazinan-2-one
[0087] (S)-3-((S)-1-(4-(1-ethyl-6-oxo-1,6-dihydropyridazin-3-yl)phenyl)ethyl)-6-(2-hydroxy-2-methylpropyl)-6-phenyl-1,3-oxazinan-2-one
[0088] (S)-6-(2-hydroxy-2-methylpropyl)-3-((S)-1-(4-(1-isopropyl-2-oxo-1,2-dihydropyridin-4-yl)phenyl)ethyl)-6-phenyl-1,3-oxazinan-2-one
[0089] (S)-6-(2-hydroxy-2-methylpropyl)-3-((S)-1-(4-(6-oxo-1-(2,2,2-trifluoroethyl)-1,6-dihydropyridin-3-yl)phenyl)ethyl)-6-phenyl-1,3-oxazinan-2-one
[0090] 6-(4-((S)-1-((S)-6-(4-fluorophenyl)-6-(2-hydroxy-2-methylpropyl)-2-oxo-1,3-oxazinan-3-yl)ethyl)phenyl)pyrazine-2-carboxamide
[0091] 2-(4-((S)-1-((S)-6-(2-hydroxy-2-methylpropyl)-2-oxo-6-phenyl-1,3-oxazinan-3-yl)ethyl)phenyl)-N,N-dimethylthiazole-5-carboxamide
[0092] (S)-6-(2-hydroxy-2-methylpropyl)-3-((S)-1-(4-(2-oxo-1-(2,2,2-trifluoroethyl)-1,2-dihydropyridin-4-yl)phenyl)ethyl)-6-phenyl-1,3-oxazinan-2-one
[0093] (S)-3-((S)-1-(4-(1-ethyl-2-oxo-1,2-dihydropyridin-4-yl)phenyl)ethyl)-6-(2-hydroxy-2-methylpropyl)-6-phenyl-1,3-oxazinan-2-one
[0094] (S)-3-((S)-1-(4-(1,6-dimethyl-2-oxo-1,2-dihydropyridin-4-yl)phenyl)ethyl)-6-(2-hydroxy-2-methylpropyl)-6-phenyl-1,3-oxazinan-2-one
[0095] 6-(4-((S)-1-((S)-6-(4-fluorophenyl)-6-(2-hydroxy-2-methylpropyl)-2-oxo-1,3-oxazinan-3-yl)ethyl)phenyl)pyrazine-2-carbonitrile
[0096] (S)-3-((S)-1-(4-(1-ethyl-6-oxo-1,6-dihydropyridin-3-yl)phenyl)ethyl)-6-(4-fluorophenyl)-6-(2-hydroxy-2-methylpropyl)-1,3-oxazinan-2-one
[0097] (S)-3-((S)-1-(4-(1,5-dimethyl-6-oxo-1,6-dihydropyridin-3-yl)phenyl)ethyl)-6-(2-hydroxy-2-methylpropyl)-6-phenyl-1,3-oxazinan-2-one
[0098] (S)-6-(4-fluorophenyl)-6-(2-hydroxy-2-methylpropyl)-3-((S)-1-(4-(1-methyl-6-oxo-1,6-dihydropyridazin-3-yl)phenyl)ethyl)-1,3-oxazinan-2-one
[0099] 6-(4-((S)-1-((S)-6-(2-hydroxy-2-methylpropyl)-2-oxo-6-phenyl-1,3-oxazinan-3-yl)ethyl)phenyl)-N,N-dimethylnicotinamide
[0100] (S)-6-(4-fluorophenyl)-6-(2-hydroxy-2-methylpropyl)-3-((S)-1-(4-(6-methylpyridazin-3-yl)phenyl)ethyl)-1,3-oxazinan-2-one
[0101] 4-(4-((S)-1-((S)-6-(2-hydroxy-2-methylpropyl)-2-oxo-6-phenyl-1,3-oxazinan-3-yl)propyl)phenyl)-2,6-dimethylpyridine 1-oxide
[0102] 5-(4-((S)-1-((S)-6-(4-fluorophenyl)-6-(2-hydroxy-2-methylpropyl)-2-oxo-1,3-oxazinan-3-yl)ethyl)phenyl)pyrazine-2-carbonitrile
[0103] 5-fluoro-2-(4-((S)-1-((S)-6-(2-hydroxy-2-methylpropyl)-2-oxo-6-phenyl-1,3-oxazinan-3-yl)ethyl)phenyl)pyridine 1-oxide
[0104] (S)-6-(2-hydroxy-2-methylpropyl)-3-((S)-1-(4-(5-methylpyrazin-2-yl)phenyl)ethyl)-6-phenyl-1,3-oxazinan-2-one
[0105] (S)-6-(2-hydroxy-2-methylpropyl)-3-((S)-1-(4-(1-isopropyl-6-oxo-1,6-dihydropyridin-3-yl)phenyl)ethyl)-6-phenyl-1,3-oxazinan-2-one
[0106] 6-(4-((S)-1-((S)-6-(2-hydroxy-2-methylpropyl)-2-oxo-6-phenyl-1,3-oxazinan-3-yl)ethyl)phenyl)-N-methylnicotinamide
[0107] (S)-6-(2-hydroxy-2-methylpropyl)-3-((S)-1-(4-(2-methylpyrimidin-5-yl)phenyl)ethyl)-6-phenyl-1,3-oxazinan-2-one
[0108] (S)-6-(2-hydroxy-2-methylpropyl)-3-((S)-1-(4-(1-methyl-2-oxo-1,2-dihydropyridin-4-yl)phenyl)propyl)-6-phenyl-1,3-oxazinan-2-one
[0109] (S)-6-(2-hydroxy-2-methylpropyl)-3-((S)-1-(4-(1-methyl-6-oxo-1,6-dihydropyridazin-3-yl)phenyl)ethyl)-6-phenyl-1,3-oxazinan-2-one
[0110] (S)-6-(2-hydroxy-2-methylpropyl)-3-((S)-1-(4-(1-methyl-6-oxo-1,6-dihydropyridin-3-yl)phenyl)propyl)-6-phenyl-1,3-oxazinan-2-one
[0111] (S)-3-((S)-1-(4-(1-ethyl-6-oxo-1,6-dihydropyridin-3-yl)phenyl)ethyl)-6-(2-hydroxy-2-methylpropyl)-6-phenyl-1,3-oxazinan-2-one
[0112] (S)-3-((S)-1-(4-(1-ethyl-6-oxo-1,6-dihydropyridin-3-yl)phenyl)propyl)-6-(2-hydroxy-2-methylpropyl)-6-phenyl-1,3-oxazinan-2-one
[0113] 6-(4-((S)-1-((S)-6-(2-hydroxy-2-methylpropyl)-2-oxo-6-phenyl-1,3-oxazinan-3-yl)ethyl)phenyl)nicotinamide
[0114] (S)-3-((S)-1-(4-(5-fluoropyridin-2-yl)phenyl)ethyl)-6-(2-hydroxy-2-methylpropyl)-6-phenyl-1,3-oxazinan-2-one
[0115] (S)-6-(2-hydroxy-2-methylpropyl)-3-((S)-1-(4-(2-methylpyrimidin-4-yl)phenyl)ethyl)-6-phenyl-1,3-oxazinan-2-one
[0116] (S)-6-(2-hydroxy-2-methylpropyl)-6-phenyl-3-((S)-1-(4-(pyrimidin-4-yl)phenyl)ethyl)-1,3-oxazinan-2-one
[0117] (S)-6-(2-hydroxy-2-methylpropyl)-3-((S)-1-(4-(6-methylpyridazin-3-yl)phenyl)ethyl)-6-phenyl-1,3-oxazinan-2-one
[0118] (S)-6-(2-hydroxy-2-methylpropyl)-6-phenyl-3-((S)-1-(4-(pyrazin-2-yl)phenyl)ethyl)-1,3-oxazinan-2-one
[0119] (S)-6-(2-hydroxy-2-methylpropyl)-3-((S)-1-(4-(1-methyl-2-oxo-1,2-dihydropyridin-4-yl)phenyl)ethyl)-6-phenyl-1,3-oxazinan-2-one
[0120] 6-(4-((S)-1-((S)-6-(2-hydroxy-2-methylpropyl)-2-oxo-6-phenyl-1,3-oxazinan-3-yl)ethyl)phenyl)nicotinonitrile
[0121] (S)-3-((S)-1-(4-(2,6-dimethylpyridin-4-yl)phenyl)ethyl)-6-(2-hydroxy-2-methylpropyl)-6-phenyl-1,3-oxazinan-2-one
[0122] (S)-3-((S)-1-(4-(2,6-dimethylpyridin-4-yl)phenyl)ethyl)-6-(4-fluorophenyl)-6-(2-hydroxy-2-methylpropyl)-1,3-oxazinan-2-one
[0123] 4-(4-((S)-1-((S)-6-(2-hydroxy-2-methylpropyl)-2-oxo-6-phenyl-1,3-oxazinan-3-yl)ethyl)phenyl)-2,6-dimethylpyridine 1-oxide
[0124] 6-(4-((S)-1-((S)-6-(4-fluorophenyl)-6-(2-hydroxy-2-methylpropyl)-2-oxo-1,3-oxazinan-3-yl)ethyl)phenyl)nicotinonitrile
[0125] 4-(4-((S)-1-((S)-6-(4-fluorophenyl)-6-(2-hydroxy-2-methylpropyl)-2-oxo-1,3-oxazinan-3-yl)ethyl)phenyl)-2,6-dimethylpyridine 1-oxide
[0126] 4-(4-((S)-1-((S)-6-(4-fluorophenyl)-6-(2-hydroxy-2-methylpropyl)-2-oxo-1,3-oxazinan-3-yl)ethyl)phenyl)-2-methylpyridine 1-oxide
[0127] (S)-6-(2-hydroxy-2-methylpropyl)-3-((S)-1-(4-(1-methyl-6-oxo-1,6-dihydropyridin-3-yl)phenyl)ethyl)-6-phenyl-1,3-oxazinan-2-one
[0128] (S)-6-(4-fluorophenyl)-6-(2-hydroxy-2-methylpropyl)-3-((S)-1-(4-(pyridin-2-yl)phenyl)ethyl)-1,3-oxazinan-2-one
[0129] (S)-6-(4-fluorophenyl)-6-(2-hydroxy-2-methylpropyl)-3-((S)-1-(4-(6-methoxypyridin-3-yl)phenyl)ethyl)-1,3-oxazinan-2-one
[0130] (S)-6-(2-hydroxy-2-methylpropyl)-6-phenyl-3-((S)-1-(4-(pyridin-2-yl)phenyl)ethyl)-1,3-oxazinan-2-one
[0131] (S)-6-(2-hydroxy-2-methylpropyl)-3-((S)-1-(4-(6-methoxypyridin-3-yl)phenyl)ethyl)-6-phenyl-1,3-oxazinan-2-one
[0132] (S)-6-(2-hydroxy-2-methylpropyl)-3-((S)-1-(4-(2-methylpyridin-4-yl)phenyl)ethyl)-6-phenyl-1,3-oxazinan-2-one
[0133] (S)-6-(4-fluorophenyl)-6-(2-hydroxy-2-methylpropyl)-3-((S)-1-(4-(2-methylpyridin-4-yl)phenyl)ethyl)-1,3-oxazinan-2-one
[0134] (S)-6-(4-fluorophenyl)-6-(2-hydroxy-2-methylpropyl)-3-((S)-1-(4-(1-methyl-6-oxo-1,6-dihydropyridin-3-yl)phenyl)ethyl)-1,3-oxazinan-2-one
[0135] (S)-3-((S)-1-(4′-fluorobiphenyl-4-yl)ethyl)-6-(2-hydroxy-2-methylpropyl)-6-phenyl-1,3-oxazinan-2-one
[0136] (S)-3-((S)-1-(2′,4′-difluorobiphenyl-4-yl)ethyl)-6-(4-fluorophenyl)-6-(2-hydroxy-2-methylpropyl)-1,3-oxazinan-2-one
[0137] As used herein, “β-haloalcohol compound,” refers to compound represented by structural formula (II)
[0000]
[0000] wherein X includes any suitable leaving group as described herein, not just halogen.
[0138] Suitable leaving groups include, but are not limited to halides, alkylsulfonates, trifluoromethanesulfonate (triflate) and phenylsulfonates which are optionally substituted with a methyl, halogen, nitro and the like, for example, methanesulfonate (mesylate), p-toluenesulfonate (tosylate), p-bromobenzenesulfonate (brosylate), p-nitrobenzenesulfonate (nosylate) and the like.
[0139] Typically, leaving groups are Cl, Br, I or —OSO 2 R, wherein R is (C 1 -C 4 )alkyl optionally substituted with one or more F, or phenyl optionally substituted with halogen, (C 1 -C 4 )alkyl or NO 2 . Most typically, leaving groups are Cl, Br, I or —OSO 2 R.
[0140] The term “biaryl group” as used herein refers to a group where an optionally substituted aryl or optionally substituted heteroaryl is bonded to another optionally substituted aryl or optionally substituted heteroaryl (e.g., biphenyl).
[0141] The term “alkyl” as used herein refers to a straight chain or branched saturated hydrocarbyl group having 1-10 carbon atoms and includes, for example, methyl, ethyl, n-propyl, isopropyl, n-butyl, sec-butyl, isobutyl, tert-butyl, n-pentyl, n-hexyl, n-heptyl, n-octyl, n-nonyl, n-decyl and the like.
[0142] The term “cycloalkyl” means a monocyclic, bicyclic or tricyclic, saturated hydrocarbon ring having 3-10 carbon atoms and includes, for example, cyclopropyl (c-Pr), cyclobutyl, cyclopentyl, cyclohexyl, cycloheptyl, cyclooctyl, bicyclo[2.2.2]octyl, bicyclo[2.2.1]heptyl, spiro [4.4]nonane, adamantyl and the like.
[0143] The term “aryl” means an aromatic radical which is a phenyl group, a naphthyl group, an indanyl group or a tetrahydronaphthalene group. An aryl group is optionally substituted with 1-4 substituents. Exemplary substituents include alkyl, alkoxy, alkylthio, alkylsulfonyl, halogen, trifluoromethyl, dialkylamino, nitro, cyano, CO 2 H, CONH 2 , N-monoalkyl-substituted amido and N,N-dialkyl-substituted amido.
[0144] The term “heteroaryl” means a 5- and 6-membered heteroaromatic radical which may optionally be fused to a saturated or unsaturated ring containing 0-4 heteroatoms selected from N, O, and S and includes, for example, a heteroaromatic radical which is 2- or 3-thienyl, 2- or 3-furanyl, 2- or 3-pyrrolyl, 2-,3-, or 4-pyridyl, 2-pyrazinyl, 2-, 4-, or 5-pyrimidinyl, 3- or 4-pyridazinyl, 1H-indol-6-yl, 1H-indol-5-yl, 1H-benzimidazol-6-yl, 1H-benzimidazol-5-yl, 2-, 4-, 5-, 6-, 7- or 8-quinazolinyl, 2-, 3-, 5-, 6-, 7- or 8-quinoxalinyl, 2-, 3-, 4-, 5-, 6-, 7- or 8-quinolinyl, 1-, 3-, 4-, 5-, 6-, 7- or 8-isoquinolinyl, 2-, 4-, or 5-thiazolyl, 2-, 3-, 4-, or 5-pyrazolyl, 2-, 3-, 4-, or 5-imidazolyl. A heteroaryl is optionally substituted. Exemplary substituents include alkyl, alkoxy, alkylthio, alkylsulfonyl, halogen, trifluoromethyl, dialkylamino, nitro, cyano, CO 2 H, CONH 2 , N-monoalkyl-substituted amido and N,N-dialkyl-substituted amido, or by oxo to form an N-oxide.
[0145] The term “heterocyclyl” means a 4-, 5-, 6- and 7-membered saturated or partially unsaturated heterocyclic ring containing 1 to 4 heteroatoms independently selected from N, 0, and S. Exemplary heterocyclyls include pyrrolidine, pyrrolidin-2-one, 1-methylpyrrolidin-2-one, piperidine, piperidin-2-one, dihydropyridine, tetrahydropyridine, piperazine, 1-(2,2,2-trifluoroethyl)piperazine, 1,2-dihydro-2-oxopyridine, 1,4-dihydro-4-oxopyridine, piperazin-2-one, 3,4,5,6-tetrahydro-4-oxopyrimidine, 3,4-dihydro-4-oxopyrimidine, tetrahydrofuran, tetrahydropyran, tetrahydrothiophene, tetrahydrothiopyran, isoxazolidine, 1,3-dioxolane, 1,3-dithiolane, 1,3-dioxane, 1,4-dioxane, 1,3-dithiane, 1,4-dithiane, oxazolidin-2-one, imidazolidin-2-one, imidazolidine-2,4-dione, tetrahydropyrimidin-2(1H)-one, morpholine, N-methylmorpholine, morpholin-3-one, 1,3-oxazinan-2-one, thiomorpholine, thiomorpholine 1,1-dioxide, tetrahydro-1,2,5-thiaoxazole 1,1-dioxide, tetrahydro-2H-1,2-thiazine 1,1-dioxide, hexahydro-1,2,6-thiadiazine 1,1-dioxide, tetrahydro-1,2,5-thiadiazole 1,1-dioxide isothiazolidine 1,1-dioxide, 6-oxo-1,6-dihydropyridazin-3-yl, 6-oxo-1,6-dihydropyridazin-4-yl, 5-oxo-4,5-dihydro-1H-1,2,4-triazol-3-yl and 5-oxo-4,5-dihydro-1H-imidazol-2-yl. A heterocyclyl can be optionally substituted with 1-4 substituents. Exemplary substituents include alkyl, haloalkyl, halogen and oxo.
[0146] The term “alkoxy group” (also herein referred to as “alkoxy”) as used herein, refers to an alkyl-O— group or a cycloalkyl-O— group, where the preferred alkyl and cycloalkyl groups and optional substituents thereon are those given above. An alkoxy group can be unsubstituted or substituted with one or more substituents.
[0147] The term “alkenyl group” (also herein referred to as “alkenyl”) as used herein, refers to a straight chain or branched hydrocarbyl group which includes one or more double bonds. Typically, an alkenyl group includes between 2 and 12 carbon atoms (i.e., (C 2 -C 12 )-alkenyl). Suitable alkenyl groups include but are not limited to n-butenyl, cyclooctenyl and the like. An alkenyl group can be unsubstituted or substituted with one or more substituents.
[0148] The term “alkynyl” group (also herein referred to as “alkynyl”) as used herein, refers to a straight chain or branched hydrocarbyl group which includes one or more triple bonds. The triple bond of an alkynyl group can be unconjugated or conjugated to another unsaturated group. Suitable alkynyl groups include, but are not limited to, (C 2 -C 8 )-alkynyl groups, such as ethynyl, propynyl, butynyl, pentynyl, hexynyl, methylpropynyl, 4-methyl-1-butynyl,4-propyl-2-pentynyl- , and 4-butyl-2-hexynyl. An alkynyl group can be unsubstituted or substituted with one or more substituents.
[0149] The term “alkylene group” (also herein referred to as “alkylene) as used herein, refers to a group represented by —[CH 2 ]—, wherein z is a positive integer, preferably from one to eight, more preferably from one to four.
[0150] The terms “cycloalkyl alkyl”, “alkoxy alkyl” and the like, that is, terms that consist of a combination of terms as defined above refer to groups that contain the groups referred to by the terms. For example, a (C a -C b )alkoxy(C c -C d )alkyl is a group that includes an alkoxy group with between a and b carbon atoms that is covalently bonded to an alkyl group with between c and d carbon atoms.
[0151] The above groups can be unsubstituted or optionally substituted. Suitable substituents are those which do not substantially interfere with the reactions described herein, that is, that do not substantially decrease the yield (e.g., a decrease of greater than 50%) or cause a substantial amount of by-product formation (e.g., where by-products represent at least 50% of the theoretical yield). However, “interfering” substituents can be used, provided that they are first converted to a protected form. Suitable protecting groups are known in the art and are disclosed, for example, in Greene and Wuts, “Protective Groups in Organic Synthesis”, John Wiley & Sons (2007).
[0152] Suitable substituents for above groups include, for example, unless otherwise indicated, (C 1 -C 4 )alkyl, (C 1 -C 4 )alkoxy, (C 1 -C 4 )alkoxycarbonyl, benzyloxycarbonyl, hydroxy(C 1 -C 4 )alkyl, cyano(C 1 -C 4 )alkyl, (C 1 -C 4 )alkylamino, di(C 1 -C 4 )alkylamino, halogen, cyano, oxo, nitro, hydroxy, amino, MeSO 2 —, MeSO 2 N(Me)(C 1 -C 4 )alkyl, MeSO 2 NH(C 1 -C 4 )alkyl, H 2 NC(═O)CMe 2 (C 1 -C 4 )alkyl, H 2 NC(═O)CHMe(C 1 -C 4 )alkyl, H 2 NC(═O)CH 2 (C 1 -C 4 )alkyl, —OR, —NR 2 , —COOR, —CONR 2 , —SO k R (k is 0, 1 or 2), wherein each R is independently —H, an alkyl group, a cycloalkyl group or an aryl group.
[0153] When a disclosed compound or its pharmaceutically acceptable salt is named or depicted by structure, it is to be understood that solvates or hydrates of the compound or its physiologically acceptable salts are also included. “Solvates” refer to crystalline forms wherein solvent molecules are incorporated into the crystal lattice during crystallization. Solvate may include water or nonaqueous solvents such as ethanol, isopropanol, DMSO, acetic acid, ethanolamine, and EtOAc. Solvates, wherein water is the solvent molecule incorporated into the crystal lattice, are typically referred to as “hydrates.” Hydrates include stoichiometric hydrates as well as compositions containing variable amounts of water.
[0154] Certain of the disclosed compounds may exist in various stereoisomeric forms. Stereoisomers are compounds that differ only in their spatial arrangement. Enantiomers are pairs of stereoisomers whose mirror images are not superimposable, most commonly because they contain an asymmetrically substituted carbon atom that acts as a chiral center. “Enantiomer” means one of a pair of molecules that are mirror images of each other and are not superimposable.
[0155] Diastereomers are stereoisomers that are not related as mirror images, most commonly because they contain two or more asymmetrically substituted carbon atoms. The symbol “*” in a structural formula represents the presence of a chiral carbon center. “R” and “S” represent the configuration of substituents around one or more chiral carbon atoms. Thus, “R*” and “S*” denote the relative configurations of substituents around one or more chiral carbon atoms.
[0156] The compounds of the invention may be prepared as individual isomers by either isomer-specific synthesis or resolved from an isomeric mixture. Conventional resolution techniques include forming the salt of a free base of each isomer of an isomeric pair using an optically active acid (followed by fractional crystallization and regeneration of the free base), forming the salt of the acid form of each isomer of an isomeric pair using an optically active amine (followed by fractional crystallization and regeneration of the free acid), forming an ester or amide of each of the isomers of an isomeric pair using an optically pure acid, amine or alcohol (followed by chromatographic separation and removal of the chiral auxiliary), or resolving an isomeric mixture of either a starting material or a final product using various well known chromatographic methods.
[0157] When the stereochemistry of a disclosed compound is named or depicted by structure, the named or depicted stereoisomer is at least 60%, 70%, 80%, 90%, 99% or 99.9% by weight pure relative to the other stereoisomers. When a single enantiomer is named or depicted by structure, the depicted or named enantiomer is at least 60%, 70%, 80%, 90%, 99% or 99.9% by weight optically pure. Percent optical purity by weight is the ratio of the weight of the enantiomer over the weight of the enantiomer plus the weight of its optical isomer.
[0158] When a disclosed compound is named or depicted by structure without indicating the stereochemistry, and the compound has at least one chiral center, it is to be understood that the name or structure encompasses one enantiomer of compound free from the corresponding optical isomer, a racemic mixture of the compound and mixtures enriched in one enantiomer relative to its corresponding optical isomer.
[0159] When a disclosed compound is named or depicted by structure without indicating the stereochemistry and has at least two chiral centers, it is to be understood that the name or structure encompasses a diastereomer free of other diastereomers, a pair of diastereomers free from other diastereomeric pairs, mixtures of diastereomers, mixtures of diastereomeric pairs, mixtures of diastereomers in which one diastereomer is enriched relative to the other diastereomer(s) and mixtures of diastereomeric pairs in which one diastereomeric pair is enriched relative to the other diastereomeric pair(s).
[0160] The compounds of the invention may be present in the form of pharmaceutically acceptable salts. For use in medicines, the salts of the compounds of the invention refer to non-toxic “pharmaceutically acceptable salts.” Pharmaceutically acceptable salt forms include pharmaceutically acceptable acidic/anionic or basic/cationic salts.
[0161] Pharmaceutically acceptable basic/cationic salts include, the sodium, potassium, calcium, magnesium, diethanolamine, n-methyl-D-glucamine, L-lysine, L-arginine, ammonium, ethanolamine, piperazine and triethanolamine salts.
[0162] Pharmaceutically acceptable acidic/anionic salts include, the acetate, benzenesulfonate, benzoate, bicarbonate, bitartrate, bromide, calcium edetate, camsylate, carbonate, chloride, citrate, dihydrochloride, edetate, edisylate, estolate, esylate, fumarate, glyceptate, gluconate, glutamate, glycollylarsanilate, hexylresorcinate, hydrobromide, hydrochloride, hydroxynaphthoate, iodide, isethionate, lactate, lactobionate, malate, maleate, malonate, mandelate, mesylate, methylsulfate, mucate, napsylate, nitrate, pamoate, pantothenate, phosphate/diphospate, polygalacturonate, salicylate, stearate, subacetate, succinate, sulfate, hydrogensulfate, tannate, tartrate, teoclate, tosylate, and triethiodide salts.
[0163] Protecting groups for an hydroxyl group —OH and reactions and conditions for protecting and deprotecting the hydroxyl group are well known in the art and are disclosed, for example, in Greene and Wuts, “Protective Groups in Organic Synthesis”, John Wiley & Sons (2007), Chapter 2 and references cited therein. For example, a protecting group may protect a hydroxyl group as ether. Such protecting groups include, but are not limited to methyl, methoxymethyl, methylthiomethyl, (phenyldimethylsilyl)methoxymethyl, benzyloxymethyl, p-methoxybenzyloxymethyl, [3,4-dimethoxybenzyl)oxy]methyl, p-nitrobenzyloxymethyl, o-nitrobenzyloxymethyl, [(R)-1-(2-nitrophenyl)ethoxy]methyl, (4-methoxyphenoxy)methyl, guaiacolmethyl, [(p-phenylphenyl)oxy]methyl, t-butoxymethyl, 4-pentenyloxymethyl, siloxymethyl, 2-methoxyethoxymethyl, 2-cyanoethoxymethyl, bis(2-chloroethoxy)methyl, 2,2,2-trichloroethoxymethyl, 2-(trimethylsilyl)ethoxymethyl, menthoxymethyl, O-bis(2-acetoxyethoxy)methyl, tetrahydropyranyl, fluorous tetrahydropyranyl, 3-bromotetrahydropyranyl, tetrahydrothiopyranyl, 1-methoxycyclohexyl, 4-methoxytetrahydropyranyl, 4-methoxytetrahydrothiopyranyl, 4-methoxytetrahydrothiopyranyl, S,S-dioxide, 1-[(2-chloro-4-methyl)phenyl]-4-methoxypiperidin-4-yl, 1-(2-fluorophenyl)-4-methoxypiperidin-4-yl, 1-(4-chlorophenyl)-4-methoxypiperidin-4-yl, 1,4-dioxan-2-yl, tetrahydrofuranyl, tetrahydrothiofuranyl, 2,3,3a,4,5,6,7,7a-octahyrdo-7,8,8-trimethyl-4,7-methanobenzofuran-2-yl, 1-ethoxyethyl, 1-(2-chloroethoxy)ethyl, 2-hydroxyethyl, 2-bromoethyl, 1[2-(trimethylsilyl)ethoxy]ethyl, 1-methyl-1-methoxyethyl, 1-methyl-1-benzyloxyethyl, 1-methyl-1-benzyloxy-2-fluoroethyl, 1-methyl-1-phenoxyethyl, 2,2,2-trichloroethyl, 1,1,-dianisyl-2,2,2,-trichloroethyl, 1,1,1,3,3,3-hexafluoro-2-phenylisopropyl, 1-(2-cyanoethoxy)ethyl, 2-trimethylsilylethyl, 2-(benzylthio)ethyl, 2-(phenylselenyl)ethyl, t-butyl, cyclohexyl, 1-methyl-1′-cyclopropylmethyl, allyl, prenyl, cinnamyl, 2-phenallyl, propargyl, p-chlorophenyl, p-methoxyphenyl, p-nitrophenyl, 2,4-dinitrophenyl, 2,3,5,6-tetrafluoro-4-(trifluoromethyl)phenyl, benzyl, p-methoxybenzyl, 3,4-dimethoxybenzyl, 2,6-dimethoxybenzyl, o-nitrobenzyl, p-nitrobenzyl, pentadienylnitrobenzyl, pentadienylnitropiperonyl, halobenzyl, 2,6-dichlorobenzyl, 2,4-dichlorobenzyl, 2,6-difluorobenzyl, p-cyanobenzyl, fluoros benzyl, 4-fluorousalkoxybenzyl, trimethylsilylxylyl, p-phenylbenzyl, 2-phenyl-2-propyl (cumyl), p-acylaminobenzyl, p-azidobenzyl, 4-azido-3-chlorobenzyl, 2-and 4-trifluoromethylbenzyl, p-(methylsulfinyl)benzyl, p-siletanylbenzyl, 4-acetoxybenzyl, 4-(2-trimethylsilyl)ethoxymethoxybenzyl, 2-naphthylmethyl, 2- and 4-picolyl, 3-methyl-2-picolyl N-oxido, 2-quinolinylmethyl, 6-methoxy-2-(4-methylpheny)-4-quinolinemethyl, 1-pyrenylmethyl, diphenylmethyl, 4-methoxydiphenylmethyl, 4-phenyldiphenylmethyl, p,p′ -dinitrobenzhydryl, 5-dibenzosuberyl, triphenylmethyl, tris(4-t-butylphenyl)methyl, α-naphthyldiphenylmethyl, p-methoxyphenyldiphenylmethyl, di(p-methoxyphenyl)phenylmethyl, tri(p-methoxyphenyl)methyl, 4-(4′-bromophenacyloxy)phenyldiphenylmethyl, 4,4′,4″-tris(4,5-dichlorophthalimidophenyl)methyl, 4,4′,4″-tris(levulinoyloxyphenyl)methyl, 4,4′,4″tris(benzoyloxyphenyl)methyl, 4,4′-dimethoxy-3″-[N-(imidazolylmethyl)trityl, 4,4′-dimethoxy-3″-[N-(imidazolylethyl)carbamoyl]trityl, bis(4-methoxyphenyl)-1′-pyrenylmethyl, 4-(17-tetrabenzo[a,c,g,i]fluorenylmethyl)-4,4″-dimethoxytrityl, 9-anthryl, 9-(9-phenyl)xanthenyl, 9-phenylthioxanthyl, 9-(9-phenyl-10-oxo)anthryl, 1,3-benzodithiolan-2-yl, 4,5-bis(ethoxycarbonyl-[1,3]-dioxolan-2-yl, benzisothiazolyl S,S-dioxido,_trimethylsilyl, triethylsilyl, triisopropylsilyl, dimethylisopropylsiyl, diethylisopropylsilyl, dimethylthexylsilyl, 2-norbornyldimethylsily, t-butyldimethylsilyl, t-butyldiphenylsilyl, tribenzylsilyl, tri-p-xylylsilyl, triphenylsilyl, diphenylmethylsilyl, di-t-butylmethylsilyl, bis(t-butyl)-1-pyrenylmethoxysilyl, tris(trimethylsilyl)silyl, sisyl, (2-hydroxystyryl)dimethylsilyl, (2-hydroxystyryl)diisopropylsily, t-butylmethoxyphenylsilyl, t-butoxydiphenylsilyl, 1,1,3,3-tetraisopropyl-3-[2-(triphenylmethoxy)ethoxy]disiloxane-1-yl, fluorous silyl. Alternatively, suitable protecting groups protect the hydroxyl group as esters, for example, formate, benzoylformate, acetate, chloroacetate, dichloroacetate, trichloroacetate, trichloroacetamidate, trifluoroacetate, methoxyacetate, triphenylmethoxyacetate, phenoxyacetate, p-chlorophenoxyacetate, phenylacetate, p-P-phenylacetate, diphenylacetate, 3-phenylpropionate, bisfluorous chain type propanoyl (Bfp-OR), 4-pentenoate, 4-oxopentanoate (levulinate), 4,4-(ethylenedithio)pentanoate, 5-[3-Bis(4-methoxyphenyl)hydroxymethylphenoxy]levulinate, pivaloate, 1-adamantoate, crotonate, 4-methoxycrotonate, benzoate, p-phenylbenzoate, 2,4,6-trimethylbenzoate (mesitoate), 4-bromobenzoate, 2,5-difluorobenzoate, p-nitrobenzoate, picolinate, nicotinate, 2-(azidomethyl)benzoate, 4-azidobutyrate, (2-azidomethyl)phenylacetate, 2-{[(tritylthio)oxy]methyl}benzoate, 2-{[(4-methoxytritylthio)oxy]methyl}benzoate,2-{[methyl(tritylthio)amino]methyl}benzoate, 2{{[4-methoxytrityl)thio]methylamino}-methyl}benzoate, 2-(allyloxy)phenylacetate, 2-(prenyloxymethyl)benzoate, 6-(levulinyloxymethyl)-3-methoxy-2- and 4-nitrobenzoate, 4-benzyloxybutyrate, 4-trialkylsiloxybutrate, 4-acetoxy-2,2-dimethylbutyrate, 2,2-dimethyl-4-pentenoate, 2-iodobenzoate, 4-nitro-4-methylpentanoate, o-(dibromomethyl)benzoate, 2-formylbenzenesulfonate, 4-methylthiomethoxy)butyrate, 2-methylthiomethoxymethyl)benzoate, 2-(chloroacetoxymethyl)benzoate, 2[(2-chloroacetoxy)ethyl]benzoate, 2-[2-(benzyloxy)ethyl]benzoate, 2-[2-(4-methoxybenzyloxy)ethyl]benzoate, 2,6-dichloro-4-methylphenoxyacetate, 2,6-dichloro-4-(1,1,3,3-tetramethylbutyl)phenoxyacetate, 2,4-bis(1,1-imethylpropyl)phenoxyacetate, chlorodiphenylacetate, isobutyrate, monosuccinoate, (E)-2-methyl-2-butenoate tigloate), o-(methoxycarbonyl)benzoate, p-P-benzoate, a-naphthoate, nitrate, alkyl N,N,N′,N′-tetramethylphosphorodiamidate, 2-chlorobenzoate, as sulfonates, sulfenates and sulfinates such as sulfate, allylsulfonate, ethanesulfonate (mesylate), benzylsulfonate, tosylate, 2-[(4-nitrophenyl)ethyl]sulfonate, 2-trifluoromethylsulfonate, 4-monomethoxytritylsulfenate, alkyl 2,4-initrophenylsulfenate, 2,2,5,5-tetramethylpyrrolidin-3-one-l-sulfinate, borate, dimethylphosphinothioyl, as carbonates such as alkyl methyl carbonate, methoxymethyl carbonate, 9-fluorenylmethyl carbonate, ethyl carbonate, bromoethyl carbonate, 2-(methylthiomethoxy)ethyl carbonate, 2,2,2-trichloroethyl carbonate, 1,1-dimethyl-2,2,2-trichloroethyl carbonate, 2-(trimethylsilyl)ethyl carbonate, 2-[dimethyl(2-naphthylmethyl)silyl]ethyl carbonate, 2-(phenylsulfonyl)ethyl carbonate, 2-(triphenylphosphonio)ethyl carbonate, cis-[4-[[(-methoxytrityl)sulfenyl]oxy]tetraydrofuran-3-yl]oxy carbonate, isobutyl carbonate, t-butyl carbonate, vinyl carbonate, allyl carbonate, cinnamyl carbonate, propargyl carbonate, p-chlorophenyl carbonate, p-nitrophenyl carbonate, 4-ethoxyl-l-naphthyl carbonate, 6-bromo-7-hydroxycoumarin-4-ylmethyl carbonate, benzyl carbonate, o-nitrobenzyl carbonate, p-nitrobenzyl carbonate, p-methoxybenzyl carbonate, 3,4-dimethoxybenzyl carbonate, anthraquinon-2-ylmethyl carbonate, 2-dansylethyl carbonate, 2-(4-nitrophenyl)ethyl, 2-(2,4-nitrophenyl)ethyl, 2-(2-nitrophenyl)propyl, 2-(3,4-methylenedioxy-6-nitrophenylpropyl, 2-cyano-1-phenylethyl carbonate, 2-(2-pyridyl)amino-l-phenylethyl carbonate, 2-[N-methyl-N-(2-pyridyl]amino-1-phenylethyl carbonate, phenacyl carbonate, 3′,5′-dimethoxybenzoin carbonate, methyl dithiocarbonate, S-benzyl thiocarbonate, and carbamates such as dimethylthiocarbamate, N-phenylcarbamate, and N-methyl-N-(o-nitrophenyl) carbamate.
[0164] Protecting groups for a carbonyl group and reactions and conditions for protecting and deprotecting the carbonyl group are well known in the art and are disclosed, for example, in Greene and Wuts, “Protective Groups in Organic Synthesis”, John Wiley & Sons (2007), Chapter 4 and references cited therein. For example, a protecting group may protect a carbonyl group as acetal or ketal. These acetals and ketals include acyclic acetals and ketals (e.g., dimethyl, diisopropyl, bis(2,2,2-trichloroethyl), cyclic acetals and ketals (e.g., 1,3-dioxanes, 1,3-dioxolanes, 1,3-dioxapane and the like), chiral acetals and ketals (e.g., (4R,5R)-diphenyl-1,3-dioxolane, 4,5-dimethyl-1,3-dioxolane, trans-1,2-cyclohexanediol ketal and the like), dithio acetals and ketals (e.g., S,S′-dimethyl, S,S′-diethyl, S,S′-dipropyl, 1,3-dithiane and the like), and monothio acetals and ketals.
[0165] Protecting groups for a carboxyl group and reactions and conditions for protecting and deprotecting the carboxyl group are well known in the art and are disclosed, for example, in Greene and Wuts, “Protective Groups in Organic Synthesis”, John Wiley & Sons (2007), Chapter 5 and references cited therein. For example, a protecting group may protect a carboxyl group as ester. These esters include, but are not limited to substituted methyl esters (e.g., 9-fluorenylmethyl, methoxymethyl, methoxyethoxymethyl and the like), 2-substituted ethyl esters (e.g., 2,2,2-trichloroethyl, 2-haloethyl, 2-(trimethylsilyl)ethyl and the like), 2,6-dialkylphenyl esters (e.g., 2,6-dimethylphenyl, 2,6-di-t-butyl-4-methylphenyl, pentafluorophenyl and the like), substituted benzyl esters (e.g., triphenylmethyl, diphenylmethyl, 9-anthrylmethyl and the like), silyl esters (e.g., trimethylsilyl, triethylsilyl, t-butyldimethylsilyl and the like. Alternatively, for example, a protecting group may protect a carboxyl group as amide (e.g., N,N-dimethyl, pyrrolidinyl, piperidinyl and the like) or hydrazide (e.g., N-phenyl).
[0166] Protecting groups for an amino group and reactions and conditions for protecting and deprotecting the amino group are well known in the art and are disclosed, for example, in Greene and Wuts, “Protective Groups in Organic Synthesis”, John Wiley & Sons (2007), Chapter 7 and references cited therein. For example, a protecting group may protect an amino group as carbamate (e.g., 9-fluorenylmethyl, 2,2,2-trichloroethyl, 4-phenylacetoxybenzyl, 2-methylthioethyl, m-nitrophenyl, and the like) or amide (e.g., formamide, acetamide, 3-phenylpropanamide).
[0167] Protecting groups for an aromatic heterocycle such as, for example, imidazole, pyrrole, and indole, and reactions and conditions for protecting and deprotecting the aromatic heterocycles are well known in the art and are disclosed, for example, in Greene and Wuts, “Protective Groups in Organic Synthesis”, John Wiley & Sons (2007), Chapter 7 and references cited therein. For example, a protecting group may protect an aromatic heterocycle as N-sulfonyl derivative (e.g., N,N-dimethylsulfonamide, methanesulfoneamide, mesitylenesulfonamide and the like), carbamate (e.g., benzyl, 2,2,2-trichloroethyl, 2-(trimethylsilyl)ethyl and the like), N-alkyl and N-aryl derivatives, N-trialkylsilyl, N-allyl, N-benzyl, amino acetal derivative, or amide.
[0168] Protecting groups for an amide group, and reactions and conditions for protecting and deprotecting the amide group are well known in the art and are disclosed, for example, in Greene and Wuts, “Protective Groups in Organic Synthesis”, John Wiley & Sons (2007), Chapter 7 and references cited therein. For example, a protecting group may protect an amide group as N-methylamide, N-allylamide, N-t-butylamide and the like.
[0169] Protecting groups for a sulfonamide group, and reactions and conditions for protecting and deprotecting the sulfonamide group are well known in the art and are disclosed, for example, in Greene and Wuts, “Protective Groups in Organic Synthesis”, John Wiley & Sons (2007), Chapter 7 and references cited therein. For example, a protecting group may protect a sulfonamide group as N-t-butylsulfonamide, N-diphenylmethylsulfonamide, N-benzylsulfonamide and the like. A description of example embodiments of the invention follows.
[0170] The following abbreviations have the indicated meanings:
[0000]
Abbreviation
Meaning
A %
Area percentage
Boc
tert-butoxy carbonyl or t-butoxy carbonyl
(Boc) 2 O
di-tert-butyl dicarbonate
Cbz
Benzyloxycarbonyl
CbzCl
Benzyl chloroformate
c-Pr
cyclopropyl
DAST
diethylaminosulfur trifluoride
DBU
1,8-diazabicyclo[5.4.0]undec-7-ene
DCC
N,N′-dicyclohexylcarbodiimide
DCU
N,N′-dicyclohexylurea
DIAD
diisopropyl azodicarboxylate
DIBAL-H
diisobutylaluminum hydride
DIEA
N,N-diisopropylethylamine
DMAP
4-(dimethylamino)pyridine
DMF
N,N-dimethylformamide
DMPU
1,3-dimethyl-3,4,5,6-tetrahydro-2(1H)-pyrimidinone
2,4-DNP
2,4-dinitrophenylhydrazine
DPTBS
Diphenyl-t-butylsilyl
dr
diastereomer ratio
EDC•HCl, EDCI
1-[3-(dimethylamino)propyl]-3-ethylcarbodiimide
hydrochloride
Equiv
equivalents
EtOAc
ethyl acetate
Fmoc
1-[[(9H-fluoren-9-ylmethoxy)carbonyl]oxy]-
Fmoc-OSu
1-[[(9H-fluoren-9-ylmethoxy)carbonyl]oxy]-2,5-
pyrrolidinedione
h, hr
hour(s)
HOBt
1-hydroxybenzotriazole
HATU
2-(7-Aza-1H-benzotriazole-1-yl)-1,1,3,3-
tetramethyluronium hexafluorophosphate
HBTU
2-(1H-Benzotriazol-1-yl)-1,1,3,3-tetramethyluronium
hexafluorophosphate
KHMDS
potassium hexamethyldisilazane
LAH or LiAlH 4
lithium aluminum hydride
LC-MS
liquid chromatography-mass spectroscopy
LHMDS
lithium hexamethyldisilazane
m-CPBA
meta-chloroperoxybenzoic acid
Me
methyl
MsCl
methanesulfonyl chloride
Min
minute
MS
mass spectrum
NaH
sodium hydride
NaHCO 3
sodium bicarbonate
NaN 3
sodium azide
NaOH
sodium hydroxide
Na 2 SO 4
sodium sulfate
NMM
N-methylmorpholine
NMP
N-methylpyrrolidinone
Pd 2 (dba) 3
tris(dibenzylideneacetone)dipalladium(0)
PE
petroleum ether
Quant
quantitative yield
rt
room temperature
Satd
saturated
SOCl 2
thionyl chloride
SFC
supercritical fluid chromatography
SPA
scintillation proximity assay
SPE
solid phase extraction
TBAF
tetrabutylammonium fluoride
TBS
t-butyldimethylsilyl
TBDPS
t-butyldiphenylsilyl
TBSCl
t-butyldimethylsilyl chloride
TBDPSCl
t-butyldiphenylsilyl chloride
TEA
triethylamine or Et 3 N
TEMPO
2,2,6,6-tetramethyl-1-piperidinyloxy free radical
Teoc
1-[2-(trimethylsilyl)ethoxycarbonyloxy]-
Teoc-OSu
1-[2-(trimethylsilyl)ethoxycarbonyloxy]pyrrolidin-
2,5-dione
T ext
External temperature
T int
Internal temperature
TFA
trifluoroacetic acid
Tlc, TLC
thin layer chromatography
TMS
trimethylsilyl
TMSCl
chlorotrimethylsilane or trimethylsilyl chloride
t R
retention time
TsOH
p-toluenesulfonic acid
EXEMPLIFICATION
Synthesis of Compound 8 of FIG. 1
[0171] FIG. 1 shows a preferred synthesis of a specific tertiary alcohol oxazinone compound (compound 8) known to be a 11β-HSD1 inhibitor. Compounds 3 to 8 of FIG. 1 were synthesized as described in Examples 1 to 4.
EXAMPLE 1
[0172]
[0173] 1-Chloro-5-methyl-3-phenyl-hex-5-en-3-ol (3). To a stirred suspension of magnesium turnings (46.7 g, 1.94 mol) in 1500 mL of THF (KF<100 ppm) was charged 53.0 mL of 1 M DIBAL-H in hexane under nitrogen at room temperature. Then beta-methylallylic chloride (160 g, 1.77 mol) was introduced while maintaining the internal temperature below 30° C. The resulting solution was agitated for 2 h at room temperature. The solution was titrated in the presence of 1.1′-bipyridine to indicate 0.8 M of the corresponding Grignard reagent. To a dry flask containing 307.0 g of anhydrous CeCl 3 (1.25 mol) at room temperature under nitrogen was added 1556.8 mL of the Grignard reagent (0.8 M, 1.25 mol). The resulting slurry was cooled to −10 ° C. and agitated for 0.5 h. To the slurry was added 200 g of the ketone (1.19 mol) in 200 mL of THF while maintaining the internal temperature below 0° C. After the mixture was stirred for 0.5 h, 1200 mL of 1 M HCl was added to obtain a clear solution while maintaining the internal temperature below 30° C. After the phase cut, the aqueous layer was extracted with EtOAc (500 mL). The combined organic layers were washed with brine and dried over sodium sulfate. Removal of the solvent under vacuum produced the crude product, which was chased with THF to achieve K<500 ppm. The crude product (306 g, 83wt %, 95% yield) was used directly for subsequent coupling. Analytical data for 3: 1 H-NMR spectroscopy (500 MHz, CDCl 3 ) δ 7.38-7.37 (d. J=7.8 Hz, 2H), 7.33 (t, J=7.9 Hz, 2H), 7.24 (t, J=7.4 Hz, 1 H), 4.91 (s, 1H), 4.76 (s, 1H), 3.57 (ddd, J=5.6, 10.7, and 10.7, 1H), 3.13 (ddd, J=4.7, 10.7 and 10.7 Hz, 1H), 2.66 (d, J=13.3 Hz, 1H), 2.54 (d, J=11.3 Hz, 1H), 2.53 (s, 1H), 2.36 (ddd, J=5.4, 10.6 and 13.9 Hz. 1H), 2.29 (ddd, J=5.6, 11.3 and 13.3 Hz, 1H), 1.29 (s, 3H). 13 C-NMR spectroscopy (125 MHz, CDCl 3 ) δ 144.3, 141.4, 128.0, 126.6, 124.8, 116.1, 74.2, 51.2, 46.0, 39.9, 23.9.
EXAMPLE 2
[0174]
[0175] 1-Bromo-4-((S)-1-isocyanato-ethyl)-benzene (4). To a 10 L jacketed reactor was charged 241 g of sodium bicarbonate (2.87 mol, 2.30 equiv) and 5 L of deionized water. The resulting solution was agitated for 10-20 min, until the solids dissolved (homogeneous). To the clear solution was charged 250 g (1.25 mol, 1.00 equiv) of (S)-(−)-1-(4-bromophenyl)ethylamine as a solution in 1.00 L of dichloromethane. An additional 4 L of dichloromethane was charged to the reactor. The biphasic solution was agitated and cooled to T int =2-3° C. Triphosgene (126 g, 424 mmol, 0.340 equiv) was charged to the reactor in approximately two equal portions ˜6 min apart. It should be noted that a slight exotherm was noted upon the addition of triphosgene. The resulting murky solution was agitated at T int =2-5° C. for 30 min, at which point HPLC analysis indicates >99 A % conversion (220 nm). The dichloromethane layer was cut and dried with anhydrous sulfate. The resulting solution was passed through a celite plug and concentrated to ˜1.5 L which fine particles of a white solid developed. The solution was filtered and concentrated to a thick oil via reduced pressure to produce 239 g of product (93.7 wt %, 79.4% yield). The material was used in the following coupling without further purification. Analytical data for 4: 1H-NMR spectroscopy (400 MHz, CD2C12) δ 7.53 (d, J=11.4 Hz, 2H), 7.26 (d, J=8.2 Hz, 2H), 4.80 (q, J=6.7 Hz, 1H), 1.59 (d, J=6.7 Hz, 3H).
EXAMPLE 3
[0176]
[0177] (R)-3-[(S)-1-(4-Bromo-phenyl)-ethyl]-6-(2-methyl-allyl)-6-phenyl-perhydro-1,3-oxazin-2-one (6) To a dried 10 L jacketed reactor under a nitrogen atmosphere was charged 1-chloro-5-methyl-3-phenyl-hex-5-en-3-ol (3, 167 g, 81.7 wt %, 610 mmol, 1.00 equiv), 1-bromo-4-((S)-1-isocyanato-ethyl)-benzene (4, 219 g, 93.7 wt %, 911 mmol, 1.50 equiv), anhydrous tetrahydrofuran (3.00 L), and then 1,8-diazabicyclo[5.4.0]undec-7-ene (DBU, 409 mL, 2.73 mol, 4.50 equiv). The resulting solution was agitated and refluxed (T int =67-69° C., T ext =75° C.) for 19 h, at which point HPLC analysis indicates ˜1 A % (220 nm) of the 1-chloro-5-methyl-3-phenyl-hex-5-en-3-ol (3) remains. The dark solution was cooled to Tint=20-25° C. Two liters of tetrahydrofuran were removed by distillation under reduced pressure. The remaining dark solution was diluted with 4.0 L of ethyl acetate and 1.0 L of hexanes. The resulting solution was washed with 4.0 L of a 1.0 M aqueous solution of hydrogen chloride (note: the wash is slightly exothermic). The aqueous solution was cut and the remaining organic solution was dried with anhydrous sodium sulfate, filtered and then concentrated to an oil via reduced pressure. The resulting material was subjected to flash silica chromatography (5-30% ethyl acetate/hexanes, 1.74 kg of silica) to produce 137.8 g of material (59 wt %, 3.1:1 diastereomeric ratio favoring the desired diastereomer 6, 32.3% yield). The material was used in the following epoxidation without further purification.
[0178] Analytical data for (R)-3-[(S)-1-(4-bromo-phenyl)-ethyl]-6-(2-methyl-allyl)-6-phenyl-perhydro-1,3-oxazin-2-one (6): 1H-NMR spectroscopy (500 MHz, CD2C12) δ 7.42-7.35 (m, 3H), 7.33-7.31 (m, 2H), 7.25-7.23 (m, 2H), 6.80-6.74 (m, 2), 5.55 (q, J=7.1 Hz, 1 H), 5.37-5.36 (m, 1H), 4.89 (s, 1H), 4.69 (s, 1H), 2.96-2.93 (m, 1H), 2.61 (dd, J=13.8 and 26.4 Hz, 2H), 2.37-2.25 (m, 3H), 1.68 (s, 3H), 1.50 (d, J=7.1
[0179] Hz, 3H). 13C-NMR spectroscopy (125 MHz, CD2C12) δ 152.5, 141.5, 140.1, 138.3, 130.6, 128.1, 128.0, 126.9, 124.4, 120.2, 115.3, 82.4, 52.1, 50.1, 35.6, 29.8, 23.4, 14.5.
[0180] Analytical data for (S)-3-[(S)-1-(4-bromo-phenyl)-ethyl]-6-(2-methyl-allyl)-6-phenyl-perhydro-1,3-oxazin-2-one (5): 1H-NMR spectroscopy (400 MHz, CD2C12) δ 7.50-7.48 (m, 2H), 7.43-7.39 (m, 2H), 7.35-7.32 (m, 3H), 7.20-7.18 (m, 2H), 5.60 (q, J=7.1 Hz, 1H), 4.85 (s, 1H), 4.66 (s, 1H), 2.73-2.67 (m, 2H), 2.60 (dd, J=13.9 and 19.4 Hz, 2H), 2.28 (dt, J=3.3 and 13.7 Hz, 1H), 2.14-2.05 (m, 1H), 1.66 (s, 3H), 1.24 (d, J=7.2 Hz, 3H). 13C-NMR spectroscopy (100 MHz, CD2C12) δ 153.4, 142.5, 141.0, 140.1, 131.8, 129.3, 128.9, 127.8, 125.3, 121.5, 116.3, 83.9, 53.2, 51.0, 36.6, 31.3, 24.3, 15.4.
EXAMPLE 4
[0181]
[0182] (S)-3-[(S)-1-(4-Bromo-phenyl)-ethyl]-6-(2-hydroxy-2-methyl-propyl)-6-phenyl-perhydro-1,3-oxazin-2-one (8; B100135541). To a 1.0 L 2-neck RBF was charged (R)-3-[(S)-1-(4-bromo-phenyl)-ethyl]-6-(2-methyl-allyl)-6-phenyl-perhydro-1,3-oxazin-2-one (6, 135.8 g, 59 wt %, 3.1:1 dr, 193 mmol, 1.00 equiv), dichloromethane (700 mL), and then 3-chloroperbenzoic acid (MCPBA, 70%, 95.3 g, 386 mmol, 2.0 equiv). The resulting solution was agitated at RT (T int =20-25° C.) for 1 h, which HPLC analysis indicates >99 A % (220 nm) conversion. The resulting solution was diluted with 700 mL of methyl tert-butyl ether (MTBE) and washed with 1×500 mL of 30 wt % solution of sodium thiosulfate and 1×500 mL of saturated aqueous solution of sodium bicarbonate. The wash sequence were repeated until the peak on an HPLC trace of the organic solution that corresponds to a HPLC sample peak of MCPBA is <2.5 A % (220 nm), which in this example the wash sequence was repeated 3 times. The resulting organic layer was dried with anhydrous sodium sulfate, filtered and then concentrated to an oil via reduced pressure. The resulting material was diluted with 200 mL of anhydrous tetrahydrofuran and then concentrated to a thick oil via reduced pressure to provide (S)-3-[(S)-1-(4-bromo-phenyl)-ethyl]-6-(2-methyl-oxiranylmethyl)-6-phenyl-perhydro-1,3-oxazin-2-one (7) which was used directly in the following reduction.
[0183] To a 2.0 L 3-neck oven-dried RBF was charged the crude (S)-3-[(S)-1-(4-bromo-phenyl)-ethyl]-6-(2-methyl-oxiranylmethyl)-6-phenyl-perhydro-1,3-oxazin-2-one (7) and 750 mL of anhydrous tetrahydrofuran. The resulting solution was agitated and cooled to T int =2-3° C. To the agitated clear solution was charged 1.0 M lithium triethylborohydride in tetrahydrofuran (Super Hydride, 348 mL, 348 mmol, 1.8 equiv). The addition is exothermic and addition controlled to maintain T int =<8° C. The resulting solution was agitated at T int =2-3° C. for 1.5 h and then allowed to warm to T int =10-13° C. over a 2.5 h, which HPLC analysis indicates ˜94 A % (220 nm) conversion. To the agitated solution was charged a solution of hydrogen peroxide (95.7 mL of a 35 wt % aqueous solution diluted with 400 mL of water, 1.08 mol, 5.60 equiv). The addition is highly exothermic and addition controlled to maintain T int =<25° C. The resulting solution was diluted with 1.00 L of methyl tert-butyl ether (MTBE) and washed with 1.00 L of water followed by 500 mL of a ˜30 wt % solution of sodium thiosulfate. The organic solution was dried with anhydrous sodium sulfate, filtered, and then concentrated via reduced pressure. The resulting material was subjected to flash silica chromatography (10-60% ethyl acetate, 600 g of silica) to produce 68 g of material consisting of both diastereomers (1.98:1 dr) and 41 g of the desired diastereomer (>99:1 dr). The material consisting of the mixed fractions was recrystallized from 250 mL of isopropyl acetate (IPAC) and 200 mL of heptane (anti-solvent) to produce upon filtration 31.3 g of product (95.7 A % at 220 nm, 74:1 dr). The two samples were combined to produce 72.3 g of product (83.6% yield for the two step operation). Analytical data for 8: 1H-NMR spectroscopy (400 MHz, CDCl3) δ 7.37-7.29 (m, 5H), 7.25-7.21 (m, 2H), 6.82-6.79 (m, 2H), 5.61 (q, J=6.9 Hz, 1H), 2.83 (ddd, J=2.5, 5.4 and 11.6 Hz, 1H), 2.39 (ddd, J=5.7, 12.0 and 14.1 Hz, 1H), 2.27 (ddd, J=2.6, 4.8 and 14.0 Hz, 1H), 2.21-2.14 (m, 3H), 2.08 (s, 1H), 1.49 (d, J=7.0 Hz, 3H), 1.18 (s, 3H), 1.13 (s, 3H). 13C-NMR spectroscopy (100 MHz, CDCl3) 6 153.2, 142.6, 138.5, 131.6, 129.13, 129.10, 128.0, 125.3, 121.6, 84.2, 71.4, 54.1, 53.3, 36.4, 33.6, 32.1, 30.8, 15.6.
SYTHESIS OF OXAZINONES: Reaction of a β-haloalcohol and an isocyanate
EXAMPLE 5
6-allyl-6-(4-fluorophenyl)-3-((S)-1-phenylethyl)-1,3-oxazinan-2-one
[0184]
[0185] Step 1. 1-Chloro-3-(4-fluorophenyl)hex-5-en-3-ol.
[0186] To a solution of 1,1′-bi-2-naphthol (0.2280 g, 0.80 mmol, 0.26 equiv), CH 2 Cl 2 (5 mL) and titanium(IV) isopropoxide (0.2243 g, 0.79 mmol, 0.26 equiv) were added 2-propanol (3.1620 g, 52.6 mmol, 17 equiv), tetraallylstannane (1.2538 g, 4.43 mmol, 1.43 equiv), and 3-chloro-1-(4-fluorophenyl)propan-1-one (0.5760 g, 3.09 mmol, 1.0 equiv) successively. The reaction mixture was stirred at rt under nitrogen for 22 h. The reaction was quenched with satd aq NH 4 and extracted with EtOAc. The organic layer was dried over Na 2 SO 4 . After the solvents were evaporated, the residue was purified by chromatography on silica gel eluted with hexanes/ethyl acetate to afford 1-chloro-3-(4-fluorophenyl)hex-5-en-3-ol as an oil.
[0187] Step 2. 6-Allyl-6-(4-fluorophenyl)-3-((S)-1-phenylethyl)-1,3-oxazinan-2-one.
[0188] A mixture of 1-chloro-3-(4-fluorophenyl)hex-5-en-3-ol (0.0889 g, 0.39 mmol, 1.0 equiv), (S)-(−)α-methylbenzyl isocyanate (0.0823 g, 0.56 mmol, 1.44 equiv), and DBU (0.1397 g, 0.92 mmol, 2.36 equiv) in THF (2 mL) was heated to reflux for 17 h. After the solvent was removed, the residue was purified by chromatography on silica gel eluted with hexanes/ethyl acetate to give 0.0990 g (75%) of the product as a mixture of diastereomers. Selected fractions contained the individual diastereomers.
[0189] Isomer 1: (R)-6-allyl-6-(4-fluorophenyl)-3-((S)-1-phenylethyl)-1,3-oxazinan-2-one. LC-MS Method 1, t R =1.89 min, m/z=340 (M+1). 1 H NMR (CDCl 3 ) 7.36-7.27 (m, 7H), 7.10-7.05 (m, 2H), 5.79-5.67 (m, 2H), 5.09-4.98 (m, 2H), 2.72-2.68 (m, 2H), 2.64-2.53 (m, 2H), 2.22-2.16 (m, 1H), 2.09-2.01 (m, 1H), 1.26 (d, J=7.3 Hz, 3H).
[0190] Isomer 2: (S)-6-allyl-6-(4-fluorophenyl)-3-((S)-1-phenylethyl)-1,3-oxazinan-2-one. LC-MS Method 1, t R =1.86 min, m/z=340 (M+1). 1 H NMR (CDCl 3 ) 7.29-7.24 (m, 2H), 7.14-7.08 (m, 3H), 7.05-7.00 (m, 2H), 6.88-6.85 (m, 2H), 5.77-5.63 (m, 2H), 5.10-5.00 (m, 2H), 2.93-2.88 (m, 1H), 2.65-2.52 (m, 2H), 2.32-2.17 (m, 3H), 1.51 (d, J =7.0 Hz, 3H).
EXAMPLE 6
6-allyl-3-((S)-1-(4-bromophenyl)ethyl)-6-(4-fluorophenyl)-1,3-oxazinan-2-one
[0191]
[0192] Step 1. 1-chloro-3-(4-fluorophenyl)hex-5-en-3-ol
[0193] A 250-mL flask was charged with anhydrous CeCl 3 (5.58 g, 22.6 mmol) and THF (40 mL). The mixture was vigorously stirred for 3.5 h at rt. The suspension was then cooled to−78° C. and a solution of allylmagnesium bromide (1.0 M in THF, 21 mL, 21.0 mmol) was added. After stirring for 2 h at −78° C., a solution of 3-chloro-1-(4-fluorophenyl)propan-1-one (2.522 g, 13.5 mmol) in THF (30 mL) was added via cannula. The reaction mixture was allowed to slowly warm to 8° C. while stirring overnight (18 h). The reaction was then quenched with satd aq NaHCO 3 , extracted with EtOAc, and dried over Na 2 SO 4 . After the solvents were evaporated, the residue was purified by chromatography on silica gel eluted with hexanes/ethyl acetate to afford of 1-chloro-3-(4-fluorophenyl)hex-5-en-3-ol (3.0049 g, 97%) as an oil. LC-MS Method 1 t R =1.79 min, m/z 213, 211 (M-OH) + ; 1 H NMR (400 MHz, CDCl 3 ) δ 7.37-7.32 (m, 2H), 7.07-7.02 (m, 2H), 5.57-5.47 (m, 1H), 5.20-5.19 (m, 1H), 5.16 (m, 1H), 3.59-3.52 (m, 1H), 3.24-3.18 (m, 1H), 2.70 (dd, J=13.8, 5.9 Hz, 1H), 2.50 (dd, J=13.8, 8.5 Hz, 1H), 2.29 (t, J=7.9 Hz, 2H), 2.22 (s, 1H); 19 F NMR (376 MHz, CDCl 3 ) δ −116.52 (m).
[0194] Step 2. (R)-6-allyl-3-((S)-1-(4-bromophenypethyl)-6-(4-fluorophenyl)-1,3-oxazinan-2-one and (S)-6-allyl-3 -((S)-1-(4-bromophenypethyl)-6-(4-fluorophenyl)-1,3-oxazinan-2-one
[0195] A mixture of 1-chloro-3-(4-fluorophenyl)hex-5-en-3-ol (0.4129 g, 1.8 mmol, 1.0 equiv), (S)-(−)-1-(4-bromophenyl)ethyl isocyanate (0.5005 g, 2.2 mmol, 1.2 equiv), and DBU (0.7375 g, 4.8 mmol, 2.7 equiv) in THF (10 mL) was heated to reflux for 25 h. The mixture was diluted with EtOAc and washed with 1 N aq HCl. The aqueous phase was extracted with EtOAc (2×). The combined organic phase was dried over Na 2 SO 4 . After the solvents were evaporated, the crude product was directly used in the next step without further purification.
[0196] An analytical sample was purified by chromatography on silica gel eluted with hexanes/ethyl acetate to afford the two diastereomers of 6-allyl-3-((S)-1-(4-bromophenyl)ethyl)-6-(4-fluorophenyl)-1,3-oxazinan-2-one.
[0197] Isomer 1: (S)-6-allyl-3-((S)-1-(4-bromophenyl)ethyl)-6-(4-fluorophenyl)-1,3-oxazinan-2-one. LC-MS Method 1 t R =2.03 min, m/z 420, 418 (MH + ); 1 H NMR (400 MHz, CDCl 3 ) δ 7.46 (d, J=8.2 Hz, 2H), 7.31-7.28 (m, 2H), 7.17 (d, J=8.2 Hz, 2H), 7.07 (t, J=8.5 Hz, 2H), 5.76-5.66 (m, 2H), 5.10-4.99 (m, 2H), 2.75-2.52 (m, 4H), 2.23-2.19 (m, 1H), 2.08-2.00 (m, 1H), 1.24 (d, J=7.0 Hz, 3H); 19 F NMR (376 MHz, CDCl 3 ) δ −115.07 (m).
[0198] Isomer 2: (R)-6-allyl-3-((S)-1-(4-bromophenypethyl)-6-(4-fluorophenyl)-1,3-oxazinan-2-one. LC-MS Method 1 t R =1.98 min, m/z 420, 418 (MH + ); 1 H NMR (400 MHz, CDCl 3 ) δ 7.25-7.20 (m, 4H), 7.05-7.01 (m, 2H), 6.71 (d, J=8.5 Hz, 2H), 5.74-5.64 (m, 1H), 5.58 (q, J=7.0 Hz, 1H), 5.09-4.99 (m, 2H), 2.92-2.87 (m, 1H), 2.63-2.50 (m, 2H), 2.33-2.16 (m, 3H), 1.47 (d, J=7.0 Hz, 3H); 19 F NMR (376 MHz, CDCl 3 ) δ −114.91 (m).
EXAMPLE 7
6 -methyl-6-phenyl-3-m-tolyl-1,3-oxazinan-2-one
[0199]
[0200] Step 1. 2-Phenylpent-4-en-2-ol
[0201] To a solution of acetophenone (30 g, 0.25 mol) in dry THF (250 mL) at −78° C. was added dropwise 1M allylmagnesium bromide (1.25 L, 1.25 mol). After addition was complete, the mixture was allowed to stir at rt for 3 h. The reaction was quenched with satd aq NH 4 Cl solution (30 mL). The mixture was extracted with EtOAc (200 mL). The organic layer was washed with brine (30 mL), dried over anhydrous Na 2 SO 4 and concentrated to give 2-phenylpent-4-en-2-ol (40.2 g), which was used for the next step without purification.
[0202] Step 2. 3-Phenylbutane-1,3-diol
[0203] A solution of 2-phenylpent-4-en-2-ol (74 g, 0.457 mol) in dry CH 2 Cl 2 (1 L) was treated with ozone at −78° C. until the mixture turned blue. The system was then flushed with oxygen to remove excess ozone. NaBH 4 (42.8 g, 1.143 mol) was added to the mixture in portions at −20° C. The mixture was stirred overnight at rt. The mixture was quenched with water and the layers were separated. The aqueous layer was extracted with CH 2 Cl 2 (2×). The organic layers were combined, washed with brine, dried over anhydrous Na 2 SO 4 and concentrated to give 3-phenylbutane-1,3-diol (67.8 g), which was used for the next step without purification.
[0204] Step 3. 3-Hydroxy-3-phenylbutyl 4-methylbenzenesulfonate
[0205] To a solution of 3-phenylbutane-1,3-diol (68 g, 0.41mol) in dry CH 2 Cl 2 (500 mL) was added dropwise a solution of TsCl (78 g, 0.41 mol) and triethylamine (71 mL, 0.45 mol) in dry CH 2 Cl 2 (500 mL) at 0° C. The mixture was stirred overnight. The mixture was poured into water and separated. The aqueous layer was extracted with CH 2 Cl 2 (200 mL) twice. The organic layer was combined, washed with brine, dried over anhydrous Na 2 SO 4 and concentrated to give the crude product. The crude product was purified by column chromatography to give 3-hydroxy-3-phenylbutyl 4-methylbenzenesulfonate (62 g, 42%). 1 H NMR (400MHz, CDCl 3 ): δ=1.55 (s, 3H), 1.93 (w, 1H), 2.19˜2.24 (q, 2H), 2.45 (s, 3H), 3.87˜4.01(m, 1H), 4.09˜4.16 (m, 1H), 7.19˜7.34 (m, 7H), 7.68˜7.76 (d, 2H).
[0206] Step 4. 6-methyl-6-phenyl-3-m-tolyl-1,3-oxazinan-2-one
[0207] To a solution of 3-hydroxy-3-phenylbutyl 4-methylbenzenesulfonate (1 g, 3.12 mmol) and DBU (1.4 g, 9.26 mmol) in CH 2 Cl 2 (15 mL) was added a solution of 3-methylphenyl isocyanate (623 mg, 4.68 mmol) in CH 2 Cl 2 (5 mL) at 0° C. over 0.5 h. The mixture was stirred at rt overnight. The mixture was concentrated to give the crude product, which was purified by column chromatography and then by preparative HPLC to afford 6-methyl-6-phenyl-3-m-tolyl-1,3-oxazinan-2-one. LC-MS Method 2, t R =2.706 min, m/z=282. 1 H NMR (CDCl 3 ) 1.75 (s, 3H), 2.30 (s, 3H), 2.35-2.50 (m, 2H), 3.30 (m, 1H), 3.50 (m, 1H), 6.95 (m, 2H), 7.05 (m, 1H), 7.20-7.30 (m, 1H), 7.35 (m, 1H), 7.42-7.50 (m, 4H).
[0208] Step 5. Enantiomers of 6-methyl-6-phenyl-3-m-tolyl-1,3-oxazinan-2-one.
[0209] Chiral preparative SFC using a ChiralPak-AD, 400×25 mm I.D, 20 μm (Daicel Chemical Industries, Ltd) column maintained at 35 C eluted with 70:30 supercritical CO 2 /0.1% diethylamine in MeOH at a flow rate of 70 mL min −1 and a nozzle pressure of 100 bar afforded two isomers.
[0210] Isomer 1 (90 mg) gave the following spectral data: 1 H NMR (400MHz, CDCl 3 ): δ=1.62 (m, 1H), 1.76 (s, 3H), 2.31 (s, 3H), 2.48 (m, 2H), 3.28 (m, 1H), 3.50 (m, 1H), 6.95 (m, 1H), 7.04 (m, 1H), 7.23 (t, 1H), 7.35 (m, 1H), 7.44 (m, 4H);
[0211] Isomer 2 (100 mg) gave the following spectral data: (400 MHz, CDCl 3 ): δ=1.62 (m, 1H), 1.76 (s, 3H), 2.31 (s, 3H), 2.48 (m, 2H), 3.28 (m, 1H), 3.50 (m, 1H), 6.95 (m, 1H), 7.04 (m, 1H), 7.23 (t, 1H), 7.35 (m, 1H), 7.44 (m, 4H).
EXAMPLE 8
[0212] 6-allyl-3-((S)-1-cyclohexylethyl)-6-(4-fluorophenyl)-1,3-oxazinan-2-one
[0000]
[0213] 1-chloro-3-(4-fluorophenyl)hex-5-en-3-ol (126 mg, 0.55 mmol), (S)-(+)-1-cyclohexylethyl isocyanate (160mg, 1.44 equiv.) and proton sponge (271 mg, 2.3 equiv.) were dissolved in dry THF (5mL) and heated to reflux for 3 h. The mixture was then cooled to 0° C. and NaH (22 mg, 1.0 equiv.) was added slowly. After 5 min, the mixture was heated to reflux overnight. LC-MS showed the reaction was complete. The mixture was diluted with EtOAc (50 mL) and washed with 1% aq HCl (2×15 mL), satd aq NaHCO 3 (10 mL) and brine (10 mL), and dried over Na 2 SO 4 . After filtration and concentration, the residue was purified by chromatography on a 12-g silica cartridge eluted with a 10-45% EtOAc in hexanes gradient to afford two isomeric products.
[0214] Isomer 1: (R)-6-allyl-3-((S)-1-cyclohexylethyl)-6-(4-fluorophenyl)-1,3-oxazinan-2-one (57.5mg, 30%). LC-MS Method 1, t R =2.05 min, m/z=346. 1 H NMR (CDCl 3 ) 7.29 (m, 2H), 7.02 (m, 2H), 5.70 (m, 1H), 5.05 (dd, 2H), 3.94 (m, 1H), 3.06 (m, 1H), 2.68-2.49 (m, 3H), 2.33 (m, 1H), 2.14 (m, 1H), 1.17 (d, 3H), 0.78(m, 2H)
[0215] Isomer 2: (S)-6-allyl-3-((S)-1-cyclohexylethyl)-6-(4-fluorophenyl)-1,3-oxazinan-2-one (56mg, 29%). LC-MS Method 1, t R =2.06 min, m/z=346. 1 H NMR (CDCl 3 ) 7.27 (m, 2H), 7.03 (t, 2H), 5.71 (m, 1H), 5.05 (dd, 2H), 3.95 (m, 1H), 2.92 (m, 1H), 2.72 (m, 1H), 2.57 (m, 2H), 2.22 (m, 2H), 1.49 (d, 1H), 1.32 (m, 1H), 0.86 (d, 3H).
EXAMPLE 9
6-(3-hydroxypropyl)-6-phenyl-3-(2-phenylcyclopropyl)-1,3-oxazinan-2-one
[0216]
[0217] Step 1
[0218] To a solution of 2-phenylcyclopropanecarboxylic acid (1.0 g, 6.17 mmol) in dry toluene (20 mL) was added triethylamine (934 mg, 9.26 mmol) and DPPA (2.0 g, 7.41 mmol) under N 2 , and the reaction mixture was refluxed for 3 h. The solution was concentrated to give (2-isocyanatocyclopropyl)benzene (800 mg), which was used for the next step without further purification.
[0219] Step 2
[0220] To a solution of (2-isocyanatocyclopropyl)benzene (800 mg, 5.03 mmol) in THF (15 mL) was added DBU (1.61 g, 10.48 mmol) and 1-chloro-3-phenylhex-5-en-3-ol (880 mg, 4.19 mmol), and the mixture was refluxed overnight. The solution was diluted with EtOAc, and washed with 1 N HCl (2×15 mL). The aqueous phase was extracted with EtOAc. The combined organic layers were washed with brine, dried over Na 2 SO 4 , filtered and concentrated to give crude product, which was purified by preparative TLC to afford 6-allyl-6-phenyl-3-(2-phenylcyclopropyl)-1,3-oxazinan-2-one (100 mg, 6%). 1 H NMR (CDCl 3 ): 1.05-1.21 (m, 3H), 1.36-1.42 (m, 1H), 2.13-2.34 (m, 1H), 2.39-2.61 (m, 2H), 2.92-3.15 (m, 1H), 3.76-4.01 (m, 1H), 4.95-5.10 (m, 2H), 5.42-5.73 (m, 1H), 6.95-6.99 (m, 1H), 7.10-7.24 (m, 10H).
[0221] Step 3
[0222] To a solution of 6-allyl-6-phenyl-3-(2-phenylcyclopropyl)-1,3-oxazinan-2-one (200 mg, 0.60 mmol) in dry THF (5 mL) was added dropwise 1 M of BH 3 /THF (1.8 mL, 1.8 mmol) at 0° C. under N 2 . After stirring at rt for 2 h, the reaction mixture was cooled to 0° C. again, and water (0.1 mL), 3 M of aqueous NaOH solution (0.1 mL), and 30% H 2 O 2 (0.3 mL) were added sequentially. After the mixture was stirred at rt for another 2 h, 1 N aqueous HCl (0.5 mL) was added. The mixture was extracted with EtOAc. The organic layer was washed with brine, dried over Na 2 SO 4 , filtered and concentrated to give the crude product, which was purified by preparative TLC followed by preparative HPLC to afford two isomers.
[0223] Isomer 1 (20 mg, 9%): LC-MS Method 3 t R =1.151, min, m/z=352.2; 1 H NMR (CDCl 3 ) 0.83 (m, 2H), 1.12 (m, 1H), 1.23 (m, 4H), 1.68 (m, 1H), 1.97 (m, 2H), 2.16 (m, 1H), 2.21 (m, 1H), 2.84 (m, 1H), 3.13 (m, 1H), 3.52 (m, 2H), 4.14 (m, 1H), 7.03 (m, 2H), 7.11 (m, 1H), 7.17 (m, 2H), 7.29 (m, 4H), 7.46-7.63 (m, 1H).
[0224] Isomer 2 (15 mg, 7%): LC-MS Method 3 t R =1.149, min, m/z=352.2; 1 H NMR (CDCl 3 ) 0.85 (m, 2H), 1.11 (m, 1H), 1.26 (m, 3H), 1.67 (m, 2H), 1.96 (m, 2H), 2.18 (m, 1H), 2.27 (m, 1H), 2.83 (m, 1H), 3.13 (m, 1H), 3.52 (m, 2H), 4.15 (m, 1H), 7.02 (m, 2H), 7.11 (m, 1H), 7.15 (m, 2H), 7.26 (m, 3H), 7.29 (m, 2H), 7.46-7.63 (m, 1H).
EXAMPLE 10
(R)-3 -((S)-1-(4-bromophenyl)propyl)-6-(3 -hydroxypropyl)-6-phenyl-1,3 -oxazinan-2-one
[0225]
[0226] Step 1
[0227] To a solution of (S)-1-phenylpropan-1-amine (3.00 g, 14 mmol) in the mixture of methylene chloride (50 mL) and saturated NaHCO 3 (50 mL) was added triphosgene (1.40 g, 4.60 mmol) at 0° C. The mixture was stirred for 15 minutes.
[0228] The organic phase was separated, dried and concentrated to give (S)-(1-isocyanatopropyl)benzene (3.0 g, 88%). 1 H NMR (CDCl 3 ): δ=0.93 (q, 3H), 1.81 (m, 2H), 4.50 (m, 1H), 7.13 (m, 2H), 7.22 (m, 1H), 7.50 (m, 2H).
[0229] Step 2
[0230] A mixture of (S)-(1-isocyanatopropyl)benzene (3.0 g, 12.5 mmol), 1-chloro-3-phenylhex-5-en-3-ol (3.6 g, 12.5 mmol) and DBU (3.80 g, 25 mmol) in tetrahydrofuran (20 mL) was heated to reflux overnight. The mixture was washed by 1 N HCl and extracted with EtOAc. The organic phase was concentrated to give the crude product which was purified by column chromatography to give (R)-6-allyl-3-((S)-1-(4-bromophenyl)propyl)-6-phenyl-1,3-oxazinan-2-one (1.0 g, 20%). 1 H NMR (400MHz, CDCl 3 ): δ=0.92 (t, 3H), 1.72-2.00 (m, 4H), 2.06-2.31 (m, 4H), 2.53 (m, 2H), 2.82 (m, 1H), 4.99 (m, 2H), 5.32 (m, 1H), 5.69 (m, 1H), 6.72 (m, 1H), 7.12 (m, 4H), 7.25 (m, 4H).
[0231] Step 3
[0232] To a solution of (R)-6-allyl-3-((S)-1-(4-bromophenyl)propyl)-6-phenyl-1,3-oxazinan-2-one (100 mg, 0.242 mmol) in tetrahydrofuran (10 mL) was added BH 3 THF (3 mL, 1 mol/L) at 0° C. under nitrogen. The formed mixture was stirred for 2 h. Then the reaction was quenched by water, followed by 3 mol/L NaOH and H 2 O 2 (3 mL). The PH of the mixture was adjusted to <7 with 5% HCl. The organic phase was separated, extracted by EtOAc, and concentrated to give the crude product, which was purified by preparative HPLC to give (R)-3-((S)-1-(4-bromophenyl)propyl)-6-(3-hydroxypropyl)-6-phenyl-1,3-oxazinan-2-one (15 mg, 15%). LC-MS Method 3 t R =1.36, min, m/z=432, 434; 1 H NMR (CDCl 3 ): δ=0.99 (t, 3H), 1.29 (m, 1H), 1.63 (m, 1H), 1.98 (m, 4H), 2.20-2.42 (m, 2H), 2.48 (m, 1H), 3.08 (m, 1H), 3.49 (m, 1H), 5.30 (m, 1H), 6.92 (m, 2H), 7.26 (m, 4H), 7.35 (m, 2H).
EXAMPLE 11
(R)-3-((R)-1-(2′,4′-difluorobiphenyl-4-yl)ethyl)-6-(4-fluorophenyl)-6-(2-hydroxyethyl)-1,3-oxazinan-2-one
[0233]
[0234] Step 1
[0235] TFAA (134 mL, 948 mmol) was dissolved in CH 2 Cl 2 (600 mL) and cooled in an ice water bath. A solution of (S)-1-phenylpropan-1-amine (112.8 g, 930 mmol) in CH 2 Cl 2 (200 mL) was added dropwise and then the ice bath was removed. The reaction mixture was stirred for 3 hrs at ambient temperature. Then the above mixture was cooled in an ice bath and MsOH (160 mL, 2.5 mol) was added dropwise followed by DBDMH (130 g, 454 mmol). The reaction mixture was left stirring overnight at rt and then quenched with water and brine. The combined organic phases were dried over NaSO 4 , filtered and concentrated to give (R)-N-(1-(4-bromopheny)ethyl)-2,2,2-trifluoroacetamide (120 g, 44%) as a off-white solid. 1 H NMR (CDCl 3 ): 1.56 (m, 3H), 1.86 (m, 2H), 5.11 (m, 1H), 6.63 (m, 1H), 7.18 (m, 2H), 7.50 (m, 2H).
[0236] Step 2
[0237] (R)-N-(1-(4-bromopheny)ethyl)-2,2,2-trifluoroacetamide (20 g, 68 mmol) was dissolved in methanol (200 mL) and cooled in an ice-water bath. Then aqueous NaOH (2 M, 100 mL) was added to the above mixture. The reaction mixture was stirred overnight at ambient temperature. The reaction mixture was concentrated and then partitioned between CH 2 Cl 2 and water. The aqueous layer was extracted with addition CH 2 Cl 2 and the combined organic phases were dried over Na 2 SO 4 , filtered and concentrated to give (R)-1-(4-bromophenyl)ethan amine (9.8 g, 73%). 1 H NMR (DMSO): 1.19 (m, 3H), 3.92 (m, 1H), 7.28 (m, 2H), 7.42 (m, 2H).
[0238] Step 3
[0239] To a solution of (S)-1-(4-bromophenyl)propan-1-amine (5 g, 25 mmol) in CH 2 Cl 2 (10 mL) was added saturated aqueous NaHCO 3 (10 mL) and then triphosgene (2.45 g, 8 mmol) at 0. Then the reaction mixture was stirred for 15 minutes at 0° C. under nitrogen. The reaction mixture was extracted with CH 2 Cl 2 twice. The combined organic phases were dried over Na 2 SO 4 , filtered and concentrated to afford (R)-1-bromo-4-(1-isocyanatoethyl)benzene (2.5 g, 44%), which was used for the next step without purification.
[0240] Step 4
[0241] To a solution of (R)-1-bromo-4-(1-isocyanatoethyl)benzene (2.5 g, 11 mmol) in THF anhydrous (40 mL) was added 1-chloro-3-(4-fluorophenyl)hex-5-en-3-ol (1.69 g, 7 mmol) and DBU (5.68 g, 33 mmol) at ambient temperature and the reaction mixture was refluxed overnight. The reaction mixture was extracted with 1 N aq HCl and EtOAc. The combined organic phases were dried over Na 2 SO 4 , filtered and concentrated to afford the residue, which was purified by column chromatography to give two isomers.
[0242] Isomer 1: (R)-6-allyl-3-((R)-1-(4-bromophenyl)ethyl) -6-(4-fluorophenyl)-1,3-oxazinan-2-one (334 mg, 7%). 1 H NMR (CD 3 OD): 1.50 (m, 3H), 2.16-2.38 (m, 2H), 2.46 (m, 1H), 2.60 (m, 2H), 3.10 (m, 1H), 5.05 (m, 2H), 5.48 (m, 1H), 5.66 (m, 1H), 6.82 (m, 2H), 7.08 (m, 2H), 7.26 (m, 4H).
[0243] Isomer 2: (S)-6-allyl-3-((R)-1-(4-bromophenypethyl)-6-(4-fluorophenyl)-1,3-oxazinan-2-one.
[0244] Step 5
[0245] A solution of (R)-6-allyl-3-((R)-1-(4-bromophenyl)ethyl)-6-(4-fluorophenyl)-1,3-oxazinan-2-one (334 mg, 0.80 mmol) in dry CH 2 Cl 2 (20 mL) was treated with ozone at −78° C. until the reaction mixture became blue. Then the mixture was flushed with oxygen to remove excess ozone. To the above mixture was added NaBH 4 (273 mg, 7 mmol) at 0° C. and the reaction mixture was stirred for 4 hrs at ambient temperature under nitrogen. The reaction mixture was washed with water and then extract with CH 2 Cl 2 twice. The combined organic phases were dried over NaSO 4 , filtered and concentrated to give the residue, which was purified by preparative HPLC to afford (S)-3-((R)-1-(4-bromophenyl)ethyl)-6-(4-fluorophenyl)-6-(2-hydroxyethyl)-1,3-oxazinan-2-one (118 mg, 35%). 1 H NMR (CD3OD): 1.50 (m, 3H), 2.12 (m, 2H), 2.29 (m, 2H), 2.50 (m, 1H), 3.10 (m, 1H), 3.33 (m, 1H), 3.68 (m, 1H), 4.56 (m, 1H), 5.50 (m, 1H), 6.86 (m, 2H), 7.10 (m, 2H), 7.30 (m, 4H).
[0246] Step 6
[0247] To a solution of (S)-3-((R)-1-(4-bromophenypethyl)-6-(4-fluorophenyl)-6-(2-hydroxyethyl)-1,3-oxazinan-2-one (109mg, 0.26 mmol), 2,4-difluorophenylboronic acid (49 mg, 0.31 mmol) and Pd(PPh 3 ) 4 (30 mg, 0.03 mmol) in dioxane (8 mL) was added a solution of CsCO 3 (2 M, 1 mL) at 0. Then the reaction mixture was refluxed overnight under nitrogen. The reaction mixture was washed with water and then extract with CH 2 Cl 2 twice. The combined organic phases were dried over Na 2 SO 4 , filtered and concentrated to give the residue, which was purified by preparative HPLC to afford (S)-3-((R)-1-(2′,4′-difluorobiphenyl-4-yl)ethyl)-6-(4-fluorophenyl)-6-(2-hydroxyethyl)-1,3-oxazinan-2-one (49 mg, 42%). LC-MS Method 3 tR=1.41, min, m/z=456; 1 H NMR (CD 3 OD): 1.55 (m, 3H), 2.12 (m, 2H), 2.22-2.46 (m, 3H), 2.52 (m, 1H), 3.12 (m, 1H), 3.33 (m, 1H), 3.68 (m, 1H), 5.56 (m, 1H), 7.08 (m, 6H), 7.08 (m, 2H), 7.35 (m, 5H). 443-155-3.
[0248] (R)-3-((R)-1-(2′,4′-difluorobiphenyl-4-yl)ethyl)-6-(4-fluorophenyl)-6-(2-hydroxyethyl)-1,3-oxazinan-2-one was prepared from (S)-6-allyl-3-((R)-1-(4-bromophenyl)ethyl)-6-(4-fluorophenyl)-1,3-oxazinan-2-one following procedures analogous to those described in Steps 5 and 6 immediately above. LC-MS Method 3 t R =1.47, min, m/z=456; 1 H NMR (CD 3 OD) 1.35 (m, 3H), 2.18 (m, 2H), 2.40 (m, 1H), 2.51 (m, 1H), 2.82 (m, 2H), 3.33 (m, 1H), 3.71 (m, 1H), 4.22-4.48 (m, 1H), 5.62 (m, 1H), 7.03 (m, 2H), 7.18 (m, 2H), 7.38 (m, 4H), 7.50 (m, 3H).
EXAMPLE 12
(R)-3 -((S)-1-(4-bromophenypethyl)-6-(3 -hydroxypropyl)-6-phenyl-1,3 -oxazinan-2-one
[0249]
[0250] Step 1
[0251] To a solution of (S)-1-(4-bromophenyl)ethanamine (40 g, 0.2 mol) in methylene chloride (600 mL) and satd aq NaHCO 3 (600 mL) was added triphosgene (27 g, 0.025 mol) at 0° C. The mixture was stirred for 15 min. The organic phase was separated, dried and concentrated to give 1-bromo-4-(1-isocyanato-ethyl)-benzene (35 g, crude).
[0252] Step 2
[0253] A mixture of 1-chloro-3-phenyl-hex-5-en-3-ol (27.5 g, 130 mmol), (S)-(−)-1-(-bromophenyl)ethyl isocyanate (35 g, 160 mmol), and DBU (80 g, 325 mmol) in THF (400 mL) was heated to reflux for 25 h. The mixture was diluted with EtOAc and washed with 1 N aq HCl. The aqueous phase was extracted with EtOAc (3×). The combined organic phase was dried over Na 2 SO 4 . After the solvents were evaporated, the crude product was purified by column chromatography to give (R)-6-allyl-3-((S)-1-(4-bromophenypethyl)-6-phenyl-1,3-oxazinan-2-one (30 g, yield 45%).
[0254] Step 3
[0255] The title compound was prepared from (R)-6-allyl-3-((S)-1-(4-bromophenyl)ethyl)-6-phenyl-1,3-oxazinan-2-one following a procedure analogous to that described in Example 78. LC-MS Method 2 t R =1.36 min, m/z=440.1; 1 H NMR (CDCl 3 ) 1.26-1.39 (m, 1H), 1.42 (d, 3H), 1.58-1.71 (m, 1H), 1.85-1.95 (m, 2H), 2.11-2.45 (m, 3H), 2.79 (m, 1H), 3.52 (m, 2H), 5.54 (m, 1H), 6.67 (d, 2H), 7.12-7.31 (m, 7H).
SYNTHESIS OF BIARYLS VIA SUZUKI SYNTHESIS
EXAMPLE 13
3-(biphenyl-3-yl)-6-methyl-6-phenyl-1,3-oxazinan-2-one
[0256]
[0257] To a solution of 3-(3-bromophenyl)-6-methyl-6-phenyl-1,3-oxazinan-2-one (50 mg, 0.14 mmol) and phenylboronic acid (35 mg, 0.29 mmol) in THF (2 mL) was added a solution of NaHCO 3 (31 mg, 0.29 mmol) in H 2 O (2 mL) followed by Pd(PPh 3 )Cl 2 (9 mg, 0.01 mmol). The mixture was refluxed overnight. The mixture was concentrated to give the crude product, which was purified by column chromatography, followed by preparative HPLC to afford 3-(biphenyl-3-yl)-6-methyl-6-phenyl-1,3-oxazinan-2-one (10 mg, 20%). 1 H NMR: (400MHz, CDCl 3 ): δ 1.71 (s, 3H), 2.40 (m, 1H), 2.48 (m, 1H), 3.31 (m, 1H), 3.54 (m, 1H), 7.08 (m, 1H), 7.30 (m, 3H), 7.7.32-7.42 (m, 8H), 7.46 (m, 2H). LC-MS Method 3, t R =1.362 min, m/z=344. 1 H NMR (CDCl 3 ) 1.75 (s, 3H), 2.32-2.43 (m, 1H), 2.50 (m, 1H), 3.20 (m, 1H), 3.52 (m, 1H), 7.10 (d, 1H), 7.25-7.45 (m, 11H), 7.50 (d, 2H).
EXAMPLE 14
6-allyl-3-(2′,4′-difluorobiphenyl-3-yl)-6-phenyl-1,3-oxazinan-2-one
[0258]
[0259] Step 1. 6-allyl-3-(2′,4′-difluorobiphenyl-3-yl)-6-phenyl-1,3-oxazinan-2-one
[0260] To a solution of 6-allyl-3-(3-bromophenyl)-6-phenyl-1,3-oxazinan-2-one (50 mg, 0.134 mmol) and 2,4-difluorophenylboronic acid (40 mg, 0.215 mmol), K 2 CO 3 (0.5 mL, 2 M) in 1,4-dioxane (1.5 ml) was slowly added Pd(Ph 3 ) 2 Cl 2 (10 mg, 20%) at 0° C. under N 2 . The mixture was refluxed overnight. The mixture was concentrated to give the crude product, which was purified by TLC and preparative HPLC to afford 6-allyl-3-(2′,4′-difluorobiphenyl-3-yl)-6-phenyl-1,3-oxazinan-2-one (10 mg, 18%). 1 H NMR (400 MHz, CDCl 3 ): δ=2.40 (m, 2H), 2.55-2.72 (m, 2H), 3.26 (m, 1H), 3.47 (m, 1H), 5.05 (m, 2H), 5.76 (m, 1H), 6.76-6.90 (m, 2H), 7.04 (m, 1H), 7.28 (m, 4H), 7.36 (m, 2H).
EXAMPLE 15
6-(2-aminoethyl)-3-(2′,4′-difluorobiphenyl-3-yl)-6-phenyl-1,3-oxazinan-2-one
[0261]
[0262] Step 1. 3-(2′,4′-difluorobiphenyl-3-yl)-6-(2-hydroxyethyl)-6-phenyl-1,3-oxazinan-2-one
[0263] To a solution of 3-(3-bromophenyl)-6-(2-hydroxyethyl)-6-phenyl-1,3-oxazinan-2-one (200 mg, 0.538 mmol), 4-fluorophenylboronic acid (128 mg, 0.806 mmol), and aq. K 2 CO 3 (1 mL, 2 M) in 1,4-dioxane (3 ml) was slowly added Pd(Ph 3 ) 2 Cl 2 (20 mg, 10%) at 0° C. under N 2 . The mixture was refluxed overnight. The mixture was concentrated to give the crude product, which was purified by TLC and preparative HPLC to afford 3-(2′,4′-difluorobiphenyl-3-yl)-6-(2-hydroxyethyl)-6-phenyl-1,3-oxazinan-2-one (200 mg, 91%). 1 H-NMR (400 MHz, CDCl 3 ): δ=2.12-2.35 (m, 2H), 2.51(m, 2H), 3.26 (m, 1H), 3.47-3.6 (m, 2H), 4.25 (m, 1H), 6.83 (m, 2H), 7.06 (m, 1H), 7.26-7.51 (m, 8H).
[0264] Step 2. 2-(3-(2′,4′-difluorobiphenyl-3-yl)-2-oxo-6-phenyl-1,3-oxazinan-6-yl)ethyl methanesulfonate
[0265] To a solution of 3-(2′,4′-difluorobiphenyl-3-yl)-6-(2-hydroxyethyl)-6-phenyl-1,3-oxazinan-2-one (200 mg, 0.49 mmol) in dry CH 2 Cl 2 (4 mL) was added Et 3 N (0.234 mL, 1.46 mmol) at 0˜−5° C. A solution of methanesulfonyl chloride (67 mg, 0.59 mmol) in dry CH 2 Cl 2 (1 mL) was added dropwise at the same temperature. After addition, the mixture was allowed to warm to rt gradually. When the reaction was complete, water (10 mL) was added and the mixture was extracted with CH 2 Cl 2 (3×10 mL). The combined organic layers were washed with 10% aq citric acid, satd aq NaHCO 3 and brine, then dried over Na 2 SO 4 , filtered and concentrated to give 2-(3-(2′,4′-difluorobiphenyl-3-yl)-2-oxo-6-phenyl-1,3-oxazinan-6-yl)ethyl methanesulfonate (230 mg, 97%), which was used in the next step without purification.
[0266] Step 3. 6-(2-azidoethyl)-3-(2′,4′-difluorobiphenyl-3-yl)-6-phenyl-1,3-oxazinan-2-one
[0267] To a solution of 2-(3-(2′,4′-difluorobiphenyl-3-yl)-2-oxo-6-phenyl-1,3-oxazinan-6-yl)ethyl methanesulfonate (230 mg, 0.47 mmol) in anhydrous DMF (5 mL) was added NaN 3 (92 mg, 1.42 mmol). The reaction mixture was heated to 70° C. overnight. The reaction mixture was cooled to rt and diluted with EtOAc (30 mL), and water (20 ml). The organic phase was washed with water (3×20 mL), dried over Na 2 SO 4 and evaporated to give 6-(2-azidoethyl)-3-(2′,4′-difluorobiphenyl-3-yl)-6-phenyl-1,3-oxazinan-2-one (100 mg, 49%).
[0268] Step 4. 3-(2′,4′-difluorobiphenyl-3-yl)-6-(2-hydroxyethyl)-6-phenyl-1,3-oxazinan-2-one
[0269] To a solution of 6-(2-azidoethyl)-3-(2′,4′-difluorobiphenyl-3-yl)-6-phenyl-1,3-oxazinan-2-one (100 mg, 0.23 mmol) in 20:1 THF/H 2 O (3 mL) was added PPh 3 (72 mg, 0.28 mmol). The reaction mixture was stirred at rt overnight. The solvent was removed under reduced pressure, and the residue was purified by column chromatography on silica gel to afford 6-(2-aminoethyl)-3-(2′,4′-difluorobiphenyl-3-yl)-6-phenyl-1,3-oxazinan-2-one (30 mg, 31%). 1 H NMR (400 MHz, CDCl 3 ): δ=2.20-2.51 (m, 2H), 2.51-2.60 (m, 2H), 2.72 (m, 1H), 3.00 (m, 1H), 3.24 (m, 1H), 3.53 (m, 1H), 6.85-6.99 (m, 2H), 7.14 (m, 1H), 7.31-7.50 (m, 8H).
EXAMPLE 16
6-allyl-3-((S)-1-(2′,4′-difluorobiphenyl-4-yl)ethyl)-6-(4-fluorophenyl)-1,3-oxazinan-2-on
[0270]
[0271] Step 1. 6-allyl-3-((S))-1-(2′,4′-difluorobiphenyl-4-ypethyl)-6-(4-fluorophenyl)-1,3-oxazinan-2-one
[0272] To a solution of 6-allyl-3-((S)-1-(4-bromophenyl)ethyl)-6-(4-fluorophenyl)-1,3-oxazinan-2-one (0.3860 g, 0.92 mmol, 1.0 equiv) in THF (10 mL) were added, under a nitrogen atmosphere, 2,4-difluorophenylboronic acid (0.2708 g, 1.71 mmol, 1.86 equiv), 2 M aq Na 2 CO 3 (8 mL), and (Ph 3 P) 2 PdCl 2 (0.0308 g, 0.0438 mmol, 0.047 equiv). The mixture was stirred for 2 d at 100° C. Brine was then added, the mixture was extracted with Et 2 O (3×), and the combined ether extracts were dried over Na 2 SO 4 . After the solvents were evaporated, the crude product was directly used in the next step without further purification. LC-MS t R =2.13, 2.17 min in 3 min chromatography, m/z452 (MH + ).
[0273] Analytical samples were separated by silica gel chromatography.
[0274] Isomer 1: (S)-6-allyl-3-((S)-1-(2′,4′-difluorobiphenyl-4-yl)ethyl)-6-(4-fluorophenyl)-1,3-oxazinan-2-one. LC-MS Method 1, t R =2.17 min, m/z=452. 1 H NMR (CDCl 3 ) 7.47 (d, J=8.2 Hz, 2H), 7.42-7.30 (m, 5H), 7.08 (t, J=8.2 Hz, 2H), 6.98-6.88 (m, 2H), 5.82-5.68 (m, 2H), 5.08 (d, J=10.2 Hz, 1H), 5.02 (d, J=17.0 Hz, 1H), 2.78-2.71 (m, 2H), 2.66-2.54 (m, 2H), 2.25-2.20 (m, 1H), 2.13-2.05 (m, 1H), 1.30 (d, J =7.0 Hz, 3H).
[0275] Isomer 2: (R)-6-allyl-3-((S)-1-(2′,4′-difluorobiphenyl-4-yl)ethyl)-6-(4-fluorophenyl)-1,3-oxazinan-2-one. LC-MS Method 1, t R =2.13 min, m/z=452. 1 H NMR (CDCl 3 ) 7.33-7.23 (m, 5H), 7.03 (t, J=8.2 Hz, 2H), 6.96-6.86 (m, 4H), 5.77-5.67 (m, 2H), 5.10 (d, J=10.3 Hz, 1H), 5.04 (d, J=17.3 Hz, 1H), 2.99-2.94 (m, 1H), 2.66-2.54 (m, 2H), 2.41-2.34 (m, 1H), 2.30-2.17 (m, 2H), 1.55 (d, J=7.0 Hz, 3H).
EXAMPLE 17
3-((S)-1-(2′,4′-difluorobiphenyl-4-yl)propyl)-6-(4-fluorophenyl)-6-(2-hydroxyethyl)-1,3-oxazinan-2-one
[0276]
[0277] To a solution of (S)-3 -((S)-1-(4-bromophenyl)propyl)-6-(4-fluorophenyl)-6-(2-hydroxy ethyl) -1,3-oxazinan-2-one (60 mg, 0.14 mmol), 2,4-difluorophenylboronic acid (26 mg, 0.17 mmol) and Pd(PPh 3 ) 4 (16 mg, 0.01 mmol) in dioxane (5 mL) was added a solution of CsCO 3 (2 M, 1 mL) at 0° C. Then the reaction mixture was refluxed overnight under nitrogen. The reaction mixture was washed with water and then extract with CH 2 Cl 2 twice. The combined organic phases were dried over Na 2 SO 4 , filtered and concentrated to give the residue, which was purified by preparative HPLC to afford (S)-3-((S)-1-(2′,4′-difluorobiphenyl-4-yl) propyl) -6-(4-fluorophenyl)-6-(2-hydroxyethyl)-1,3-oxazinan-2-one (17 mg, 26%). 1 H NMR (CD 3 OD): 0.96 (m, 3H), 2.01 (m, 2H), 2.12 (m, 2H), 2.30 (m, 2H), 2.48 (m, 1H), 3.10 (m, 1H), 3.33 (m, 1H), 3.65 (m, 1H), 5.38 (m, 1H), 7.02 (m, 4H), 7.08 (m, 2H), 7.28 (m, 4H), 7.42 (m, 1H). 443-114-3.
[0278] (R)-3-((S)-1-(2′,4′-difluorobiphenyl-4-yl) propyl) -6-(4-fluorophenyl)-6-(2-hydroxyethyl)-1,3-oxazinan-2-one was prepared from (R)-3-((S)-1-(4-bromophenyl)propyl)-6-(4-fluorophenyl)-6-(2-hydroxy ethyl) -1,3-oxazinan-2-one following a procedure analogous to that described immediately above. 1 H NMR (CD 3 OD): 0.62 (m, 3H), 1.76 (m, 1H), 1.92 (m, 1H), 2.12 (m, 3H), 2.56 (m, 1H), 2.78 (m, 1H), 2.89 (m, 1H), 3.33 (m, 1H), 3.71 (m, 1H), 5.38 (m, 1H), 7.05 (m, 2H), 7.16 (m, 2H), 7.44 (m, 7H).
EXAMPLE 18
(S)-3-((S)-1-(4′-fluorobiphenyl-4-yl)ethyl)-6-(2-hydroxyethyl)-6-(thiophen-2-yl)-1,3-oxazinan-2-one
[0279]
[0280] Step 1
[0281] Pd(PPh 3 ) 2 Cl 2 (100 mg) was added to the solution of (R)-6-allyl-3-((S)-1-(4-bromophenyl)ethyl)-6-(thiophen-2-yl)-1,3-oxazinan-2-one (1.0 g, 2.5 mmol), 4-fluorophenylboronic acid (420 mg, 3.0 mmol) in 1,4-dioxane. Cs 2 CO 3 (5 mL) was slowly added. The mixture was heated to reflux for 2 h. The mixture was quenched with water and separated, extracted with EtOAc twice, dried over anhydrous Na 2 SO 4 and concentrated to afford the residue, which was purified by TLC to give (R)-6-allyl-3-((S)-1-(4′-fluorobiphenyl-4-yl)ethyl)-6-(thiophen-2-yl)-1,3-oxazinan-2-one (768 mg, 73%).
[0282] Step 2
[0283] To a solution of (R)-6-allyl-3-((S)-1-(4′-fluorobiphenyl-4-yl)ethyl)-6-(thiophen-2-yl)-1,3-oxazinan-2-one (300 mg, 0.71 mmol) was added aqueous solution of KMnO 4 (66 mg, 0.42 mmol) and NaIO 4 (537 mg, 2.52 mmol). The reaction mixture was stirred at rt overnight. The reaction mixture was filtered and concentrated, then extracted with CH 2 Cl 2 . The organic phases was dried over Na 2 SO 4 , filtered and concentrated to afford 2-((S)-3-((S)-1-(4′-fluorobiphenyl-4-yl)ethyl)-2-oxo-6-(thiophen-2-yl)-1,3-oxazinan-6-yl)acetic acid (218 mg, 70%).
[0284] Step 3
[0285] A solution of 2-((S)-3-((S)-1-(4′-fluorobiphenyl-4-yl)ethyl)-2-oxo-6-(thiophen-2-yl)-1,3-oxazinan-6-yl)acetic acid (218 mg, 0.5 mmol) in THF anhydrous (10 mL) was added BH 3 (3.0 mL) at 0 and then stirred at reflux for 2 h. Then the reaction mixture quenched by water and separated, extracted with EtOAc twice. The organic phases was dried over Na 2 SO 4 , filtered and concentrated to afford the residue, which was purified by TLC to give (S)-3-((S)-1-(4′-fluorobiphenyl-4-yl)ethyl)-6-(2-hydroxyethyl)-6-(thiophen-2-yl)-1,3-oxazinan-2-one (85 mg, 40%). LC-MS Method 3 t R =1.35, min, m/z=426, 448; 1 H NMR (CD 3 OD): 1.50 (m, 3H), 2.15 (m, 2H), 2.30 (m, 1H), 2.40 (m, 1H), 2.60 (m, 1H), 3.15 (m, 1H), 3.45 (m, 1H), 3.70 (m, 1H), 5.60 (m, 1H), 6.90 (m, 1H), 7.00 (m, 1H), 7.10 (m, 4H), 7.35 (m, 3H), 7.55 (m, 2H).
[0286] (R)-3-((S)-1-(4′-fluorobiphenyl-4-yl)ethyl)-6-(2-hydroxyethyl)-6-(thiophen-2-yl)-1,3-oxazinan-2-one was prepared following a procedure analogous to that described immediately above. LC-MS Method 3 t R =1.4, min, m/z=426, 448; 1 H NMR (CD 3 OD) 1.38 (d, 3H), 2.01 (m, 1H), 2.18 (m, 3H), 2.41 (m, 1H), 2.86 (m, 1H), 3.02 (m, 1H), 3.41 (m, 1H), 3.72 (m, 1H), 5.62 (m, 1H), 6.98 (m, 1H), 7.03 (m, 1H), 7.15 (m, 1H), 7.36 (m, 3H), 7.58 (m, 4H).
EXAMPLE 19
(R)-6-(3-hydroxypropyl)-3-((S)-1-(4-(6-oxo-1,6-dihydropyridin-3-yl)phenyl)ethyl)-6-phenyl-1,3-oxazinan-2-one
[0287]
[0288] Step 1
[0289] A mixture of (R)-6-allyl-3-((S)-1-(4-bromophenyl)ethyl)-6-phenyl-1,3-oxazinan-2-one (150 mg, 0.375 mmol) and 6-aminopyridin-3-ylboronic acid (56 mg, 0.45 mmol), Pd(Ph 3 P) 2 Cl 2 (15 mg), and aqueous Cs 2 CO 3 solution (0.5 mL, 2 M) in 1,4-dioxane (10 mL) was stirred and heated to reflux for 2 h. The organic phase was separated, and concentrated to give the crude product, which was purified by preparative HPLC to give (R)-6-allyl-3-((S)-1-(4-(6-aminopyridin-3-yl)phenyl)ethyl)-6-phenyl-1,3-oxazinan-2-one (90 mg, 60%).
[0290] Step 2
[0291] To a solution of (R)-6-allyl-3-((S)-1-(4-(6-aminopyridin-3-yl)phenyl)ethyl)-6-phenyl-1,3-oxazinan-2-one (90 mg, 0.23 mmol) in tetrahydrofuran (10 mL) was added BH 3 THF (3.0 mL, 1 mol/L, 4 mmol) at 0° C. under nitrogen atmosphere. The formed mixture was stirred for 2 h. The reaction was quenched by water. Then NaOH (2 mL, 3 mol/L) and H 2 O 2 (1 mL) was added to the above mixture. When the reaction was over, the mixture was extracted with EtOAc. The combined organic phase was concentrated to give the crude product, which was purified by preparative HPLC to give (R)-3-((S)-1-(4-(6-aminopyridin -3-yl)phenyl)ethyl)-6-3-hydroxypropyl)-6-phenyl-1,3-oxazinan-2-one (40 mg, 41%).
[0292] Step 3
[0293] (R)-3-((S)-1-(4-(6-aminopyridin-3-yl)phenyl)ethyl)-6-(3-hydroxypropyl)-6-phenyl-1,3-oxazinan-2-one (40 mg, 0.09 mmoL) was dissolved in 3.5 M H 2 SO 4 (10 mL), and 2 M NaNO 2 (10 mL) was added at 0° C. The reaction mixture was stirred at rt for 2 h and treated with NaOH solution. The mixture was extracted with EtOAc. The combined organic layer was washed with brine, dried over anhydrous Na 2 SO 4 , and concentrated to afford the residue, which was purified by preparative HPLC to give (R)-6-(3-hydroxypropyl)-3-((S)-1-(4-(6-oxo-1,6-dihydropyridin-3-yl)phenyl)ethyl)-6-phenyl-1,3-oxazinan-2-one (10 mg, 20%). LC-MS Method 2 t R =1.66, min, m/z=433, 455; 1 H NMR (CDCl 3 ): 1.36 (m, 2H), 1.50 (m, 3H), 1.68 (m, 2H), 1.92 (m, 2H), 2.10-2.30 (m, 3H), 2.84 (m, 1H), 3.50 (m, 2H), 5.12 (m, 1H), 6.62 (m, 1H), 6.86 (m, 2H), 7.08 (m, 2H), 7.18-7.32 (m, 5H), 7.46 (m, 1H), 7.62 (m, 1H).
EXAMPLE 20
[0294] (S)-3-((S)-1-(4′-fluorobiphenyl-4-yl)ethyl)-6-(2-hydroxy-2-methylpropyl)-6-phenyl-1,3-oxazinan-2-one
[0000]
[0295] Step 1
[0296] A mixture of (R)-6-allyl-3-((S)-1-(4-bromophenyl)ethyl)-6-phenyl-1,3-oxazinan-2-one (5.83 g, 15 mmol), 4-fluorophenylboronic acid (3 g, 22 mmol), PdCl 2 (PPh 3 ) 2 (1 g, 1.4 mmol), and aqueous Cs 2 CO 3 solution (2 M, 8.0 mL) in 1,4-dioxane (50 mL) was heated to reflux for 2 h. The mixture was filtered, and the filtrate was extracted with EtOAc (3×). The combined organic layer was washed with brine, dried over Na 2 SO 4 and concentrated to give the crude product, which was purified by preparative TLC to give (R)-6-allyl-3-((S)-1-(4′-fluorobiphenyl-4-yl)ethyl)-6-phenyl-1,3-oxazinan-2-one (5.3 g, 88%).
[0297] Step 2
[0298] To a solution of (R)-6-allyl-3-((S)-1-(4′-fluorobiphenyl-4-yl)ethyl)-6-phenyl-1,3-oxazinan-2-one (3 g, 7.23 mmol) in acetone (20 mL) was added a solution of KMnO 4 (685 mg, 4.34 mmol) and NaIO 4 (5.6 g, 26 mmol) in H 2 O (15 mL) dropwise at 0° C. The mixture was stirred for 4 h. When TLC showed that the starting material had disappeared, the precipitate was removed by filtration, and the acetone was removed under reduced pressure. The resulting mixture was basified to pH=13 by the addition of 1 M aq NaOH, and then washed with ether (3×50 mL). The aqueous phase was acidified to pH=1 by addition of 1 N aq HCl, and extracted with CH 2 Cl 2 (3×15 mL). The organic layers were combined, washed with brine, dried over Na 2 SO 4 and concentrated in vacuo to give 2-((S)-3-((S)-1-(4′-fluorobiphenyl-4-yl)ethyl)-2-oxo-6-phenyl-1,3-oxazinan-6-yl) acetic acid (2.8 g, 90%).
[0299] Step 3
[0300] To a solution of 2-((S)-3-((S)-1-(4′-fluorobiphenyl-4-yl)ethyl)-2-oxo-6-phenyl-1,3-oxazinan-6-yl) acetic acid (1 g, 2.3 mmol) in MeOH (15 mL) was added thionyl chloride (408 mg, 3.5 mmol) dropwise at 0° C. under N 2 atmosphere. After refluxing overnight, the mixture was concentrated to give the crude product, which was purified by chromatography to give methyl 2-((S)-3-((S)-1-(4′-fluorobiphenyl-4-yl)ethyl)-2-oxo-6-phenyl-1,3-oxazinan-6-yl) acetate (680 mg, 68%).
[0301] Step 4
[0302] To a solution of methyl 2-((S)-3-((S)-1-(4′-fluorobiphenyl-4-yl)ethyl)-2-oxo-6-phenyl-1,3-oxazinan-6-yl)acetate (180 mg, 0.4 mmol) in dry THF (5 mL) under N 2 at −78° C. was added methylmagnesium bromide (1.5 mL, 3 M, 4.5 mmol) dropwise at −78° C. After addition, the mixture was stirred for 1 h at rt. Then the reaction was quenched with water and the mixture was extracted with ethyl acetate for three times (3×5 mL). The organic layers were combined, washed with brine, dried over Na 2 SO 4 , filtered and concentrated. The residue was purified by preparative HPLC to give (S)-3-((S)-1-(4′-fluorobiphenyl-4-yl)ethyl)-6-(2-hydroxy-2-methylpropyl)-6-phenyl-1,3-oxazinan-2-one (2.48 mg, 1%). 1 H NMR (CDCl 3 ): 1.05 (s, 1H), 1.13 (s, 3H), 1.50 (d, 3H), 2.14-2.23 (m, 2H), 2.25-2.40 (m, 1H), 2.80 (m, 1H), 5.63 (m, 1H), 6.94 (m, 2H), 7.02 (m, 2H), 7.18-7.30 (m, 7H), 7.38 (m, 2H). LC-MS Method 3 t R =1.51, min, m/z=448, 470.
EXAMPLE 21
5-(4-((S)-1((R)-6-(4-fluorophenyl)-6-(3-hydroxypropyl)-2-oxo-1,3-oxazinan-3-yl)ethyl)phenyl)nicotinamide
[0303]
[0304] Step 1
[0305] To a solution of (R)-6-allyl-3-((S)-1-(4-bromophenyl)ethyl)-6-(4-fluorophenyl)-1,3-oxazinan-2-one (1 g, 2.4 mmol) in dry THF (15 mL) was added dropwise BH 3 .THF (5 mL, 1 M) at 0° C. After stirring for 2 h at rt, the reaction mixture was cooled to 0° C. and water (1 mL), aqueous NaOH (0.5 mL, 3 M) and H 2 O 2 (0.5 mL, 30%) were successively added. The mixture was stirred for 2-3 h at rt and diluted with water (8 mL). The pH was adjusted to 6-7 with 0.5 N HCl. The layers were separated, and the aqueous phase was extracted with EtOAc (3×10 mL). The combined organic layers were washed with a satd aq NaHCO 3 (20 mL) and brine (20 mL), dried over Na 2 SO 4 , and concentrated in vacuo to give the crude product, which was purified by preparative TLC to afford (R)-3-((S)-1-(4-bromophenyl)ethyl)-6-(4-fluorophenyl)-6-(3-hydroxypropyl)-1,3-oxazinan-2-one (400 mg, 38%).
[0306] Step 2
[0307] A mixture of (R)-3-((S)-1-(4-bromophenyl)ethyl)-6-(4-fluorophenyl)-6-(3-hydroxypropyl)-1,3-oxazinan-2-one (250 mg, 0.6 mmol), 5-(methoxycarbonyl)pyridin-3-ylboronic acid (163 mg, 0.9 mmol), PdCl 2 (PPh 3 ) 2 (50 mg, 20%) and aqueous Cs 2 CO 3 solution (2 M, 2 mL) in 1,4-dioxane (6 mL) was heated to reflux at 100° C. overnight under N 2 . The mixture was filtered, and the filtrate was extracted with EtOAc for 3 times. The combined organic layer was washed with brine, dried over Na 2 SO 4 and concentrated to the crude product, which was purified by preparative HPLC to give methyl 5-(4-((S)-1-((R)-6-(4-fluorophenyl)-6-(3-hydroxypropyl)-2-oxo-1,3-oxazinan-3-yl)ethyl)phenyl)nicotinate (220 mg, crude).
[0308] Step 3
[0309] Methyl 5 -(4-((S)-1-((R)-6-(4-fluorophenyl)-6-(3-hydroxypropyl)-2-oxo-1,3-oxazinan-3-yl)ethyl)phenyl)nicotinate (30 mg, 0.1 mmol) was dissolved in anhydrous NH 3 in EtOH (5 mL). Then the mixture was stirred at rt overnight. The solvent was removed in vacuo to give the crude product, which was purified by preparative HPLC to provide 5-(4-((S)-1-((R)-6-(4-luorophenyl)-6-(3-hydroxypropyl)-2-oxo-1,3-oxazinan-3-yl)ethyl)phenyl) nicotinamide (10 mg, 34%). LC-MS Method 2 t R =1.022 min, m/z=478; 1 H NMR (CD 3 OD): 1.31 (m, 1H), 1.56 (m, 3H), 1.59 (m, 1H), 1.91 (m, 2H), 2.17-2.28 (m, 1H), 2.33 (m, 1H), 2.44 (m, 1H), 3.14 (m, 1H), 3.44 (m, 2H), 5.60 (m, 1H), 7.04-7.17 (m, 4H), 7.29 (m, 2H), 7.49 (m, 2H), 8.41 (m, 1H), 8.86 (m, 1H), 8.97 (m, 1H).
EXAMPLE 22
(S)-3-((S)-1-(4-bromophenyl) ethyl)-6-(2-hydroxy-2-methylpropyl)-6-phenyl-1,3-oxazinan-2-one
[0310]
[0311] Step 1: (S)-1-bromo-4-(1-isocyanatoethyl)benzene
[0312] To a solution of (S)-1-(4-bromophenyl)ethanamine (240 g, 1.2 mol) in methylene chloride (3 L) and satd aq NaHCO 3 (3 L) solution was added triphosgene (118 g, 0.396 mol) at 0° C. The mixture was stirred for 15 min. The organic phase was separated, dried over Na 2 SO 4 and concentrated to give 1-bromo-4-(1-isocyanato-ethyl)-benzene (170 g, 63%).
[0313] Step 2: 1-chloro-3-phenylhex-5-en-3-ol
[0314] To a solution of 3-chloro-1-phenylpropan-1-one (170 g, 1.01 mol) in anhydrous THF (1200 mL) was added allylmagnesium bromide (1.2 L, 1 mol/L) at −78° C. under nitrogen. The formed mixture was stirred for 30 min at −78° C. The reaction was quenched with aqueous NaHCO 3 solution. The organic phase was separated, dried over Na 2 SO 4 and concentrated to give the crude product, which was purified by column chromatography (petroleum ether/EtOAc=100:1) to afford 1-chloro-3-phenylhex-5-en-3-ol (180 g, 86%). 1 H NMR (CDCl 3 ): 2.27 (m, 2H), 2.51 (m, 1H), 2.74 (m, 1H), 3.22 (m, 1H), 3.58 (m, 1H), 5.16 (m, 2H), 5.53 (m, 1H), 7.23 (m, 1H), 7.39 (m, 4H).
[0315] Step 3: (R)-6-allyl-3((S)-1-(4-bromophenypethyl)-6-phenyl-1,3-oxazinan-2-one
[0316] A mixture of 1-chloro-3-phenyl-hex-5-en-3-ol (105 g, 0.050 mmol), (S)-(−)-1-(-bromophenyl)ethyl isocyanate (170 g, 0.752 mol), and DBU (228 g, 1.5 mol) in THF (1700 mL) was heated to reflux overnight. The mixture was diluted with EtOAc and washed with 1N aq HCl. The aqueous phase was extracted with EtOAc (3×). The combined organic phase was dried over Na 2 SO 4 . After the solvents were evaporated, the crude product was purified by column chromatography (petroleum ether/EtOAc=20:1 to 5:1) to give (R)-6-allyl-3((S)-1-(4-bromophenyl)ethyl)-6-phenyl-1,3-oxazinan-2-one (100 g, 34%). 1 H NMR (CDCl 3 ): 1.39 (d, 3H), 2.14 (m, 1H), 2.24 (m, 2H), 2.48-2.61 (m, 3H), 2.82 (m, 2H), 5.01 (m, 2H), 5.52 (q, 1H), 5.73 (m, 1H), 6.62 (d, 2H), 7.12 (m, 2H), 7.28 (m, 2H).
[0317] Step 4: (S)-3-((S)-1-(4-bromophenyl)ethyl)-6-(2-oxopropyl)-6-phenyl-1,3-oxazinan-2-one and 3-((R)-3((S)-1-(4-bromophenyl)ethyl)-2-oxo-6-phenyl-1,3-oxazinan-6-yl)propanal
[0318] To a solution of (R)-6-allyl-3-((S)-1-(4-bromophenyl)ethyl)-6-phenyl-1,3-oxazinan-2-one (31 g, 78 mmol) and CuCl (19.3 g, 195 mmol) in dry DMF (150 mL) was added H 2 O (50 mL) and PdCl 2 (4.10 g, 23 mmol) at rt. After addition, the mixture was stirred overnight under oxygen. After TLC showed the starting material had disappeared, the solid was filtered off. Water (200 mL) and EtOAc (200 mL) was added, the organic layers were separated and the aqueous layer was extracted with EtOAc (3×40 mL). The combined organic layer was washed with brine, dried over Na 2 SO 4 , filtered and concentrated to give a residue which was purified by column chromatography (petroleum ether/EtOAc=5:1 to 1:1) to give a mixture of (S)-3((S)-1-(4-bromophenypethyl)-6-(2-oxopropyl)-6-phenyl-1,3-oxazinan-2-one and 3-((R)-3((S)-1-(4-bromophenyl)ethyl)-2-oxo-6-phenyl-1,3-oxazinan-6-yl)propanal, (26 g, 81%).
[0319] Step 5: (S)-3-((S)-1-(4-bromophenyl)ethyl)-6-(2-oxopropyl)-6-phenyl-1,3-oxazinan-2-one
[0320] To a mixture of (S)-3-((S)-1-(4-bromophenypethyl)-6-(2-oxopropyl)-6-phenyl-1,3-oxazinan-2-one and 3-((R)-3-((S)-1-(4-bromophenyl)ethyl)-2-oxo-6-phenyl-1,3-oxazinan-6-yl)propanal (20 g, 48.2 mmol) in t-BuOH (250 mL) and 2-methyl-2-butene (50 mL) was added a solution of NaClO 2 (19.3 g, 0.213 mol) and NaH 2 PO 4 (28 g, 0.179 mol) in H 2 O (300 mL) at 0° C. The formed mixture was stirred for 1 h at 0° C. The mixture was treated with water (100 mL) and extracted with CH 2 Cl 2 . The combined organic layer was dried over Na 2 SO 4 , filtered and concentrated to leave a residue, which was purified by column chromatography (petroleum ether/EtOAc=5:1 to 2.5:1) to afford (S)-3-((S)-1-(4-bromophenyl)ethyl)-6-(2-oxopropyl)-6-phenyl-1,3-oxazinan-2-one (10.0 g, 83%). 1 H NMR (CDCl 3 ): 1.49 (d, 3H), 2.12 (s, 3H), 2.33 (m, 2H), 2.63 (m, 1H), 2.86-3.08 (m, 3H), 5.57 (q, 1H), 6.66 (d, 2H), 7.19 (m, 2H), 7.33 (m, 5H).
[0321] Step 6: (S)-3-((S)-1-(4-bromophenyl) ethyl)-6-(2-hydroxy-2-methylpropyl)-6-phenyl-1,3-oxazinan-2-one
[0322] To a solution of (S)-3((S)-1-(4-bromophenyl)ethyl)-6-(2-oxopropyl)-6-phenyl-1,3-oxazinan-2-one (20 g, 46.4 mmol) in anhydrous THF (200 mL) was added dropwise methylmagnesium bromide (31 mL, 144 mmol) at −78° C. under nitrogen. Then the mixture was stirred at rt for 1 h. The reaction mixture was quenched with aq NaHCO 3 (50 mL) under ice water bath. The organic layers were separated. The aqueous layer was extracted with EtOAc (150 mL). The combined organic layers were washed with brine, dried over Na 2 SO 4 and concentrated in vacuo to give the crude product, which was purified column chromatography (petroleum ether/EtOAc=5:1 to 2:1) to afford (S)-3-((S)-1-(4-bromophenyl)ethyl)-6-(2-hydroxy-2-methylpropyl)-6-phenyl-1,3-oxazinan-2-one (13 g, 65%). After re-crystallization from EtOH, 4 g of the pure compound was obtained. 1 H NMR (CDCl 3 ): 1.06 (s, 3H), 1.12 (s, 3H), 1.44 (d, 3H), 2.14 (m, 3H), 2.21 (m, 1H), 2.33 (m, 1H), 2.76 (m, 1H), 5.54 (q, 1H), 6.74 (d, 2H), 7.16 (d, 2H), 7.28 (m, 5H).
EXAMPLE 23
REVERSE SUZUKI
6-(4-{1-[6-(2-Hydroxy-2-methyl-propyl)-2-oxo-6-phenyl-[1,3]oxazinan-3-yl]-ethyl}-phenyl)-N-methyl-nicotinamide
[0323]
[0324] Step 1
[0325] To a solution of (S)-3((S)-1-(4-bromophenyl)ethyl)-6-(2-hydroxy-2-methylpropyl)-6-phenyl-1,3-oxazinan-2-one (6.6 g, 15.2 mmol) and 4,4,4′,4′,5,5,5′,5′-octamethyl-2,2′-bi(1,3,2-dioxaborolane) (6.1g, 24.3 mmol) in dry DMSO (20 mL) was added KOAc (4.8 g, 48.6 mmol) and Pd(dppf)Cl 2 (372 mg, 0.46 mmol). After addition, the mixture was warmed to 100° C. for 20 h. After TLC showed the starting material had disappeared, the solid was filtered off Water (60 mL) and EtOAc (20mL) were added, the layers were separated and the aqueous layer was extracted with EtOAc (3×15 mL). The combined organic layer was washed with brine, dried over Na 2 SO 4 , filtered and concentrated to give (S)-6-(2-hydroxy-2-methylpropyl)-6-phenyl-3-((S)-1-(4-(4,4,5,5-tetramethyl-1,3,2-dioxaborolan-2-yl)phenyl)ethyl)-1,3-oxazinan-2-one (4.4 g, 60%), which was purified by column. 1 H NMR (CDCl 3 ): 1.03 (s, 3H), 1.12 (s, 3H), 1.22 (s, 12H), 1.49 (d, 3H), 2.13 (m, 4H), 2.26 (m, 1H), 2.73 (m, 1H), 5.64 (q, 1H), 6.91 (d, 2H), 7.38 (m, 5H), 7.51 (d, 2H).
[0326] Step 2
[0327] To a solution of (S)-6-(2-hydroxy-2-methylpropyl)-6-phenyl-3-((S)-1-(4-(4,4,5,5-tetramethyl-1,3,2-dioxaborolan-2-yl)phenyl)pethyl)-1,3-oxazinan-2-one (500 mg, 1.04 mmol) and methyl 6-bromonicotinate (292 mg, 1.35 mmol) in dry 1,4-dioxane (5 mL) was added CsCO 3 (1 mL, 2 mmol) and Pd(PPh 3 ) 2 Cl 2 (50 mg). After addition, the mixture was warmed to 110° C. for 30 min under microwave. After TLC showed the starting material had disappeared, the solid was filtered off Water (20 mL) and EtOAc (10 mL) was added, the layers were separated and the aqueous layer was extracted with EtOAc (3×10 mL). The combined organic layer was washed with brine, dried over Na 2 SO 4 , filtered and concentrated to give methyl 6-(4-((S)-1-((S)-6-(2-hydroxy-2-methylpropyl)-2-oxo-6-phenyl-1,3-oxazinan-3-yl)ethyl)phenyl)nicotinate (507 mg, 89%), which was purified by preparative TLC. 1 H NMR (CDCl 3 ): 1.13 (s, 3H), 1.19 (s, 3H), 1.61 (d, 3H), 2.24 (m, 4H), 2.37 (m, 1H), 2.88 (m, 1H), 4.02 (s, 3H), 5.76 (q, 1H), 7.11 (d, 2H), 7.29-7.47 (m, 6H), 7.78 (m, 1H), 7.82 (m, 2H), 8.38 (d, 1H), 9.31 (s, 1H).
[0328] Step 3
[0329] Methyl 6-(4-((S)-1-((S)-6-(2-hydroxy-2-methylpropyl)-2-oxo-6-phenyl-1,3-oxazinan-3-yl)ethyl)phenyl)nicotinate (150 mg, 0.307 mmol) was dissolved in NH 2 Me/MeOH (10 mL). The mixture was stirred at rt overnight. The solvent was removed in vacuo to give the crude product, which was purified by preparative HPLC and chiral HPLC to afford 6-(4-((S)-1-((S)-6-(2-hydroxy-2-methylpropyl)-2-oxo-6-phenyl-1,3-oxazinan-3-yl) ethyl)phenyl)-N-methylnicotinamide (54 mg, 36%). LC-MS Method 2 t R =1.117 min, m/z=430.1; 1 H NMR (CD 3 OD) 0.93 (s, 3H), 1.27 (s, 3H), 1.59 (d, 3H), 2.16 (s, 2H), 2.22-2.37 (m, 1H), 2.41-2.60 (m, 2H), 2.99 (s, 3H), 3.11 (m, 1H), 5.60 (m, 1H), 7.12 (d, 1H), 7.29 (m, 5H), 7.80 (m, 2H), 8.01 (d, 1H), 8.41 (d, 1H), 9.03 (s, 1H).
[0330] The teachings of all patents, published applications and references cited herein are incorporated by reference in their entirety.
[0331] While this invention has been particularly shown and described with references to example embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the scope of the invention encompassed by the appended claims. | Disclosed are syntheses of 11β-HSD1 inhibitors and corresponding intermediates that are promising for the treatment of a variety of disease states including diabetes, metabolic syndrome, obesity, glucose intolerance, insulin resistance, hyperglycemia, hypertension, hypertension-related cardiovascular disorders, hyperlipidemia, deleterious gluco-corticoid effects on neuronal function (e.g. cognitive impairment, dementia, and/or depression), elevated intra-ocular pressure, various forms of bone disease (e.g., osteoporosis), tuberculosis, leprosy (Hansen's disease), psoriasis, and impaired wound healing (e.g., in patients that exhibit impaired glucose tolerance and/or type 2 diabetes). | 2 |
BACKGROUND OF THE INVENTION
The present invention is directed to improving diaphragm cells for the electrolysis of aqueous solutions of alkali metal chlorides, for example a sodium chloride brine.
A disadvantage of electrolytic diaphragm cells resides in the difficulty of avoiding the presence of alkali metal chlorate in the alkaline liquor drawn off from the cathode compartments. The presence of alkali metal chlorate in the liquor in fact renders the latter unsuitable for various applications, particularly for the rayon industry, and consequently it necessitates a costly purification of the liquor.
The major part of the alkali metal chlorate present in the alkaline liquor arises from decomposition of hypochlorite ions formed in the anode compartment of the cell, by reaction of the chlorine dissolved in the anolyte with hydroxyl ions coming from the cathode compartment. Besides its unfavourable influence on the presence of chlorate in the alkaline liquor produced in the cell, the formation of hypochlorite ions in the anode compartment gives the disadvantage of also reducing the current efficiency of electrolysis.
In order to reduce the content of chlorate in the alkaline liquor, it has already been proposed, in U.S. Pat. No. 2,823,177 of S. G. Osborne, published Feb. 11, 1958, to incorporate cobalt or nickel in the finely divided state in the diaphragm. In Belgian Pat. No. 773918 of Oct. 14, 1971 in the name of the present applicant it has also been proposed, with the same aim, to incorporate in the diaphragm iron or copper and/or their oxides in the finely divided state.
SUMMARY OF THE INVENTION
The applicant has now found a diaphragm cell for the electrolysis of an aqueous solution of alkali metal chloride which ensures the production of an alkaline liquor having an exceptionally low content of alkali metal chlorate and which furthermore allows, all other things being equal, the obtainment of appreciably improved current efficiencies compared to those obtained with known cells.
The present invention relates therefore to a diaphragm cell for the electrolysis of an aqueous solution of alkali metal chloride comprising a chamber divided by a diaphragm into an anode compartment containing at least one anode and a cathode compartment containing at least one cathode and also comprising, in the anode compartment, a catalytic surface made of material which catalyses the decomposition of hypochlorite ion.
In the cell according to the invention, the effect of the catalytic surface is to decompose hypochlorous acid and alkali metal hypochlorite in the anode compartment itself, with liberation of oxygen, in the proportion in which these unwanted products are formed.
In a preferred embodiment of the cell according to the invention, the material which constitutes the catalytic surface comprises a metal or a metal compound which is resistant to the conditions ruling in the anolyte, and at which the oxygen over potential is not more than 1.5V in a molar solution of potassium hydroxide at a current density of 10 kA/m 2 . It is advantageously selected from the group consisting of iridium, osmium, palladium, rhodium, and ruthenium, their alloys and their compounds, and is preferably selected from among their oxides.
All other things being equal, the greater the area of the catalytic surface, the more effective is the action of this surface on the reduction of the content of alkali metal chlorate in the alkaline liquor. In general, it is advantageous for the catalytic surface to have an area at least equal to about 5% of the effective anode surface of the cell and preferably greater than about 10% of the effective anode surface. The best results are obtained when the catalytic surface has an area at least equal to 20% of the effective anode surface. For economic reasons, it is not desirable for the catalytic surface to have too great a surface area, for example greater than 300% of the effective anode surface.
By effective anode surface of the cell is meant the useful part of the anode, which effectively participates in the discharge of chloride ions under the normal conditions of operation of the cell.
In the case of a cell of the type described in Belgian Pat. No. 780912 dated Mar. 20, 1972, in the name of the present applicant, which is eqipped with an alternating sequence of anode plates and flat parallel cathodes, placed opposite each other, the effective anode surface corresponds, in general, to the total surface area of the anode plates.
On the other hand, in the case of a cell equipped with special anodes of the type described in Sourth African Patent No. 71,03637 of June 4, 1971, in the name of Richard J. Bright, comprising a vertical block of graphite carrying vertical ribs facing the cathodes, the effective anode surface corresponds to the edges of the ribs adjacent to the cathodes. Experience has in fact shown that the massive block of graphite takes part to a negligible extent, less than 2%, even nil, in the discharge of the chloride ions.
In the case of the known metal anodes, formed of a titanium support carrying a coating of a material which catalyses the discharge of chloride ions, for example platinum, it is generally the practice, for economic reasons to limit the anode coating essentially to the zone of the support which is closest to the cathode, the superficial area of the coating being fixed so as to ensure normal and economic functioning of the cell. In this particular case, the effective anode surface of the cell is in general practically restricted to this coated zone of the anode support. This is for example the case with the anode described in Belgian Pat. No. 791675 of Nov. 21, 1972, in the name of the present applicant, the said anode being formed of two vertical titanium plates, which are disposed opposite each other so as to form a box, and which carry an active coating catalysing the discharge of chloride ions only on their base external to the box.
In the cell according to the invention, the catalytic surface may for example take the form of filaments, plates, foraminous or corrugated sheets, so as to be immersed in the anolyte during electrolysis.
In the cell according to the invention, the catalytic surface may be unpolarised or, alternatively, it may be connected to the positive pole of a direct current source.
BRIEF DESCRIPTION OF THE DRAWINGS
Particular features and details of the invention will become evident from the following description of the accompanying drawings, which represent, by way of example only, some particular embodiments of the cell according to the invention.
FIG. 1 is a view in longitudinal elevation, partially cut away, of a first embodiment of the cell according to the invention,
FIG. 2 is, on a larger scale, a partial section in the plane II--II of FIG. 1;
FIG. 3 is a view, analagous to FIG. 2 of a second embodiment of the cell according to the invention.
FIG. 4 shows, on a larger scale, a detail of FIG. 3, seen in section in the plane IV--IV of FIG. 3.
FIG. 5 is a view analagous to FIGS. 2 and 3 of a third embodiment of the cell according to the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In these Figures, the same reference numerals denote identical elements.
There is depicted in FIGS. 1 and 2 a diaphragm cell with vertical electrodes of the type described in Belgium Patent No. 780912 of Mar. 20, 1972, in the name of the present applicant. The cell comprises, on a foundation 1 supported by insulators 2, a pedestal 3 of concrete forming the floor of the cell, and supporting, at its periphery, a rectangular casing 4 of steel, which is closed by a cover 5. Within the casing 4, cathodes 6 alternate with rows of substantially vertical and parallel anode plates 7, which are fixed to a current lead-in 8 buried in the concrete pedestal 3.
The anodes 7 are for example constituted by graphite plates or, preferably, by plates of titanium carrying on their two faces a known coating which is resistant to the conditions ruling in the cell and which catalyses the discharge of chloride ions. By way of example, the anode coating may comprise a metal of the platinum group or a compound, for example an oxide, of a metal of this group.
The effective anode surface of the cell is substantially equal to the total area of the two faces of the group of anode plates 7.
The cathodes 6 are formed of a steel trellis, fixed to the wall of the casing 4 and shaped so as to form cathode compartments or pockets 10 extending between the anodes 7. The cathode lattice 7 is entirely covered by a diaphragm (not shown), which thus separates the cathode compartments 10 from the anode compartment containing the anodes 7.
The anode compartment is in communication, by way of the cover 5, with a conduit 12 for admission of a sodium chloride brine and with a conduit 13 for removal of chlorine produced at the anodes 7. The cathode compartments are in communication, by way of the casing 4, with a conduit 14 for removal of hydrogen liberated at the cathode during electrolysis and with a conduit 15 for removal of an alkaline liquor.
In accordance with the invention, the anode chamber of the cell contains a horizontal foraminous plate 16 made of a material which catalyses decomposition of hypochlorite ions. The foraminous plate 16 is held, at its periphery, between the cover 5 and a peripheral flange 17 of the casing 4, with interposition of sealing joints 18' and 19', so that the plate is immersed in the anolyte during electrolysis.
The foraminous plate 16 may be constituted by a perforated or expanded sheet of a film-forming metal, coated with a material which catalyses the decomposition of hypochlorite ions in the anolyte.
The film-forming metal of the plate 16 may advantageously be selected from the group consisting of titanium, tantalum, niobium, tungsten, zirconium and their alloys.
The material which catalyses the decomposition of hypochlorite ions may advantageously be selected from the metals of the group consisting of iridium, osmium, palladium, rhodium, and ruthenium, their alloys or their oxides, for which the oxygen over potential in an aqueous solution of potassium hydroxide is at most equal to 1.5v under a current density of 10kA/m 2 . The catalytic material is preferably constituted by a mixture of an oxide of a metal of the group consisting of iridium, osmium, palladium, rhodium and ruthenium and an oxide of a film-forming metal of the group consisting of titanium, tantalum, niobium, tungsten and zirconium.
In an advantageous modification of the embodiment of FIGS. 1 and 2, the catalytic plate 16 is constituted by a lattice made of a synthetic polymer resistant to corrosion by chlorine and the anolyte, and covered with the catalytic material. The polymer constituting the lattice maybe a fluorinated polymer, for example polytetrafluoroethylene, polyvinylidenefluoride or polychlorotrifluoroethylene, such as that known by the name KEL-F (Kellog Company). The rigidity of the lattice may optionally be increased by means of cross braces.
In FIGS. 3 and 4 is shown a preferred embodiment of the cell according to the invention.
In the cell of FIGS. 3 and 4, each anode comprises a series of vertical fins 18 fixed perpendicularly to a vertical supporting plate 19. The latter is connected to a current lead-in buried in a concrete pedestal 3, as in the case of the cell of FIGS. 1 and 2. The fins 18 are formed for example by the blades of vertical U-shaped profiles welded to the supporting plate 19 along the web 20.
The effective anode surface of the cell of FIGS. 3 and 4 corresponds to the area of the free ends 17 of the fins, which are immediately adjacent to the cathodes 6. These free ends 17 of the fins thus constitute the anodes proper, where the discharge of chloride ions effectively takes place. The remaining part of the fins 18, the web 20 of the U-profile and the supporting plate 19 constitute the catalytic surface, capable of decomposing hypochlorite ions in the anolyte.
The U-profile and the supporting plate 19 may for example be made of titanium; the free ends 17 of the blades 18 are covered with a material catalysing the discharge of chloride ions, for example platinum, while the remaining part of the blades 18, the web 20 of the U-profiles and the supporting plate 19 are covered with a material catalysing the decomposition of hypochlorite ions in the anolyte, for example ruthenium oxide.
In a modification, there may be used, for the assembly of the U-profiles and the supporting plate 19, a coating which is suitable both for catalysing the discharge of chloride ions and for catalysing the decomposition of hypochlorite ions in the anolyte, for example a mixture of ruthenium oxide and titanium dioxide.
In this particular modification of the invention, the free ends 17 of the fins constitute the effective anode surface of the cell, that is to say the useful part of the fins, which participates effectively in the process of discharging chloride ions, during normal operation of the cell. The remaining part of the fins and the supporting plate 19 participate to a negligible extent, less than 2%, even not at all, in the process of discharging chloride ions.
According to another modification of the cell of FIGS. 3 and 4, the supporting plate 19 and the U-profiles are extended upwards, beyond the cathodes 6, underneath the cover 5 of the cell. The portion 21 of the supporting plate 19 and the U-profiles, which thus extends above the anodes and the cathodes is coated with a material which catalyses the decomposition of hypochlorite ions.
In the embodiment showed in FIG. 5, the cell according to the invention is equipped with anodes 7, each of which is formed by a pair of substantially vertical titanium plates 22, placed face to face so as to form a hollow box, open at its upper and lower ends, within which the anolyte circulates downwardly during electrolysis. Cross braces 23 maintain the separation between the two plates 22 of the anode boxes 7. The titanium plates 22 carry on their surface external to the anode boxes 7 a coating catalysing the discharge of chloride ions during electrolysis.
In the cell of FIG. 5, the effective anode surface is equal to the total area of the external coated surfaces of the plates 22 of the group of anode boxes 7.
According to the invention, the plates 22 are covered, on their surface facing towards the interior of the anode boxes 7, with a coating catalysing the decomposition of hypochlorite ions in the anolyte.
In an advantageous modification of the embodiment of FIG. 5, inclined fins 24 made of titanium, carrying a coating catalysing the decomposition of hypochlorite ions, are fixed, for example welded, to the plates 22, inside the anode boxes 7. All other things being equal, these fins increase the surface catalysing the decomposition of hypochlorite ions; additionally they cause turbulence in the flow of the anolyte within the anode boxes 7, improving the rate of decomposition of the hypochlorite ions in the anolyte.
In order to demonstrate the advantage of the invention comparative tests were carried out in a laboratory electrolysis cell equipped with vertical rectangular anode and cathode of area 120 cm 2 , separated by an asbestos diaphragm. The anode is formed of a titanium plate carrying a coating made of a mixture of 50% ruthenium oxide and 50% titanium dioxide by weight. The cathode is formed of a steel lattice and supports the diaphragm.
The effective anode surface of this laboratory cell is equal to the area of the anode, namely 120 cm 2 .
In each of the comparative tests, a brine containing 260g of sodium chloride per kg was electrolysed at a current density of about 2 kA/m 2 of anode surface. The temperature of the brine in the cell was maintained at about 85° C during electrolysis. An alkaline liquor containing about 11% by weight of caustic soda was drawn from the cell. In each test the current efficiency of the electrolytic operation in terms of chlorine production and the content of sodium chlorate in the alkaline liquor were measured.
FIRST SERIES OF TESTS (COMPARATIVE)
Two successive tests of electrolysis were carried out in the laboratory cell prior to the invention, in which the anode compartment was not equipped, in addition to the anode, with a surface catalysing the decomposition of hypochlorite ions in the anolyte. The results obtained in each test are recorded in Table I.
TABLE I______________________________________ Content of sodium chlorate Current efficiency in the alkaline liquorTest No. (%) (ppm)______________________________________1 94.1 3202 94.8 310______________________________________
SECOND SERIES OF TESTS (IN ACCORDANCE WITH THE INVENTION)
In accordance with the invention, a lattice of titanium carrying a coating catalysing the decomposition of hypochlorite ions in the anolyte was placed in the anode compartment of the laboratory cell.
Test No. 3
There was employed a catalytic lattice of surface area 24 cm 2 (corresponding to 20% of the effective anode surface of the cell), the coating of which consisted of a mixture of 50% by weight of ruthenium oxide and 50% by weight of titanium dioxide. During electrolysis there were recorded a current efficiency of 96.7% in respect of chlorine production and a sodium chlorate content in the alkaline liquor of 46 ppm.
Test No 4
There was employed a catalytic lattice of the same composition as that of Test No 3, but having a surface area equal to 120 cm 2 , which corresponds to 100% of the effective anode surface of the cell. During electrolysis there were recorded a current efficiency of 96.3% and a content of 30 ppm of a sodium chlorate in the alkaline liquor.
Test No 5
There was employed a catalytic lattice of titanium having the same composition of coating as in tests 3 and 4, but of surface area equal to 240 cm 2 (which corresponds to 200% of the effective anode surface of the cell). There were recorded a current efficiency of 94.4% and a content of chlorate in the alkaline liquor equal to 27 ppm.
Test No 6
There was employed a catalytic lattice of titanium of 120 cm 2 (which corresponds to 100% of the effective anode surface of the cell), carrying a coating of ruthenium oxide. The current efficiency of electrolysis in respect of chlorine rose to 95.5% and the alkaline liquor showed a content of sodium chlorate equal to 32 ppm.
In Table II are recorded the results of the second series of tests.
TABLE II______________________________________ Chlorate content of the Catalytic Current alkalineTest Catalytic surface efficiency liquorNo Material (cm.sup.2) (%) (ppm)______________________________________3 50% RuO.sub.2 /50%TiO.sub.2 24 96.7 464 " 120 96.3 305 " 240 94.4 276 RuO.sub.2 120 95.5 32______________________________________
A comparison of Tables I and II demonstrates the improvement provided by the invention in regard to the current efficiency of electrolysis and the content of alkali metal chlorate in the alkaline liquor drawn from the cathode compartment.
The invention is obviously not limited exclusively to the preceding examples, numerous modifications being possible without departing from the compass of the following claims. | A diaphragm cell for use in the electrolysis of an aqueous solution of alkali metal chloride. The cell is provided with a chamber divided by a diaphragm into an anode compartment having at least one anode therein and a cathode compartment having at least one cathode therein. The cathode has a catalytic surface different from the active surface of the anode. The cathode surface is made of a material which catalyses the decomposition of hypochlorite ions. | 2 |
FIELD OF THE INVENTION
This invention relates to a device which may be used for aiding poor readers to improve their reading ability, and to enable competent readers too, to improve their reading ability.
BACKGROUND OF THE INVENTION
The amount of printed matter is ever increasing, as is the requirement to read text on a computer screen accurately and efficiently. There are two elements to efficient reading namely reading speed, and comprehension of what is being read.
When reading, a reader's eyes move relative to stationary text. The reader's eyes do not move smoothly along the text, but rather perform a series of jerky movements consisting of jumps and stops. It is during the stops that information is taken into the brain. During reading, words tend not to be read one word at a time, but as a group of words along a line.
In the case of a poor reader, the jumps and stops do not flow along the lines of text, but sometimes backtrack and back skip. A backtrack is when the eyes jump backwards to what has been read, and a back skip is when the eyes jump backwards more than just the last group of read words. The back skip can be along a line, over several lines, or even may be a paragraph of the text.
In the case of a good reader though, the eyes are trained to move with longer jumps and hence there are less stops, for there are shorter pauses for the stops, and less or no backtracking or back skipping. Such eye movements enable information to be more smoothly conveyed to the brain, such improved presentation enables improved comprehension of the text being read.
It is common practice for a reader to use a pointer whilst reading, the pointer pointing to individual words as they are read.
SUMMARY OF THE INVENTION
According to a first aspect of the invention I provide a method of reading using a reading aid including a handle part which is adapted to be gripped manually at a location spaced from text to be read, and a cursor part attached to the handle part and extending transversely thereto, the handle part and the cursor part being attached by a joint which permits the handle part to be moved relative to the cursor part during reading, the cursor part being positionable by manipulating the handle part to indicate a part of a line of the text being read, the method including moving the cursor part along the line and/or down the text during reading to indicate successive words or groups of words, whilst manipulating the handle part relative to the cursor part so that the handle part is maintained out of the reader's line of sight whilst the cursor part is maintained generally flat against the text.
Thus by performing the method of the invention, a reader may be trained to read without backtracking and back skipping, and by moving the cursor part appropriately relative to the text, reading speed and comprehension may be improved.
Preferably the handle part is thin so that the handle part does not obscure the text being read. The handle part and the cursor part may be attached by a joint which permits the handle part to be moved universally relative to the cursor part during reading. Alternatively, the handle part and the cursor part may be attached by a joint that permits substantially universal movement of the handle part with respect to the cursor part, but restricts rotation of the handle about a longitudinal axis of the handle part.
The handle part may be attached approximately centrally along the length of the cursor part. Hence the reader's eyes are encouraged to concentrate on the centre of the text being read.
The method may be applied to the reading of any text, including the reading of text from computer screens. However the invention is particularly useful for reading columns in newspapers and magazines, in which case the cursor part may be of a length substantially equal to the width of the columns being read. Thus a reader may be encouraged to read a group of words consisting of the entire line of the column.
Alternatively, the cursor part may have a length of greater than two words of average length of text.
It will be appreciated, however, that for readers of different ability, and/or for reading different text, ideal cursor part lengths may differ. Accordingly in a preferred embodiment, the reading aid may have separable handle and cursor parts, and may be made of a cursor part selected from a set of cursor parts of different configuration, by attaching the selected cursor part to the handle part.
In each case, the cursor part of the reading aid may be opaque in which case the cursor part is, during performance of the method, positioned beneath or above the word or groups of words to be indicated, or a portion of the cursor part may be transparent so that the method may include positioning the cursor part relative to the text such that at least a portion of the line of text to be indicated is visible to the reader through the transparent portion. In yet another arrangement, the cursor part may include a frame through which text may be read.
The method may include adjusting the length of the handle part to suit an individual reader and/or to enable the length of the handle part to be extended from a retracted stowed position for use. The method may include unfolding the cursor part from a stowed position in which the cursor part and handle part are substantially parallel, to a position for use where the cursor part extends at substantially right angles relative to the handle part.
The cursor part may be a unitary structure, or may include a pair of relatively foldable wings which may be folded so as to extend generally parallel to the handle part.
The cursor part may be configured to form an image that may be appealing to children.
According to a second aspect of the invention I provide a reading aid for use in the method of the first aspect of the invention.
The aid may include a writing implement such as a highlighter, integrally provided with the handle part. For example, a writing point may be provided at an end of the handle part remote from the cursor part, or the handle part may include a main stem and a branch including the writing implement.
According to a third aspect of the invention, I provide a reading aid including a cursor part and a handle part, the cursor part being attached to the handle part by a joint, the joint being configured to permit substantially universal movement of the handle part with respect to the cursor part, about a longitudinal axis of the handle part.
According to a fourth aspect of the invention, I provide a reading aid including a cursor part and a handle part, the cursor part being configured to form an image which may be attractive to children.
According to a fifth aspect of the invention I provide a computer when programmed to aid reading or to train a reader, there being means to display on a display screen of the computer concurrently with displaying on the display screen text to be read, a cursor, the computer being programmed to position the cursor to indicate a word or group of words of the line of the text being read and to move the cursor along the line during reading successively to indicate groups of words.
Preferably the computer is programmed so that the speed at which the cursor is moved along the line of text and/or the number of words indicated may be changed as a reader's ability improves.
The computer may be programmed to move the cursor relative to the text being read in a predetermined path over the text as a whole in such manner as to improve the speed of the reading.
Although the cursor may simply indicate the word or group of words, for example by underlining, or emboldening the group of words, the cursor may frame the word or group of words.
In one arrangement text which is framed may be enlarged compared within the remaining text. This is particularly useful when reading small font text e.g. in cells in spreadsheets.
The cursor may form an image which may be attractive to children.
According to a sixth aspect of the invention, we provide a method of operating a computer according to the fifth aspect of the invention including the steps of moving a cursor relative to text to be read on a display screen, successfully to indicate words or groups of words of a line of text to be read.
The method of the sixth aspect of the invention may include changing the size and/or shape and/or colour of the cursor to suit different reader's abilities and/or the nature of the text being read.
According to a seventh aspect of the invention we provide a method of assessing reading ability including the steps of displaying on a computer display screen concurrently with text to be read, a cursor, manually moving the cursor relative to the text to indicate lengths of the text sequentially being read, and analysing from the speed and sequence of cursor movements, reading ability.
The invention will now be described with reference to the accompanying drawings in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a reading aid of the second aspect of the invention in use.
FIGS. 2 to 11 show various embodiments of reading aids for use in the method of the first aspect of the invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1 there is shown a page 10 of text to be read, the text consisting of individual words arranged in lines down the page 10 . The page may be a page of text of a printed publication such as a newspaper, magazine or book, or text on a computer screen.
To promote efficient reading, a reading aid 12 is used, the reading aid 12 including a handle part 14 which is long and thin and in this embodiment is of fixed length, and a cursor part 15 attached to the handle part 14 by means of a joint 18 . In this example, the handle part 14 is joined to the cursor part 15 , with the cursor part 15 extending generally normally relative to the handle part 14 and being positionable by manipulating the handle part 14 to indicate a part of a line of the text being read. Also in this example, the cursor part 15 extends for a length greater than two words of average length of the text, however, the length of the cursor part 15 may be greater or smaller than this.
The method of the invention is performed by a reader grasping the handle part 14 at a position spaced from the text 10 , and with the cursor part 15 positioned beneath or above a line of the text to indicate a word or group of words, as the reader reads, the cursor part 15 is moved along the line of text and down the text by manipulating the handle part 14 and the joint 18 , so that the reader's eyes are deterred from backtracking or back skipping, and are encouraged to move in regular jumps or continuously alone the line of text, in one direction.
In the remaining figures, different embodiments of reading aid 12 are illustrated, and similar parts to the reading aid 12 of FIG. 1 are indicated by the same reference numerals.
In FIG. 2 , the cursor pail 15 is attached to the handle part 14 by a joint 18 which permits of generally universal movement of the cursor part 15 relative to the handle pail 14 so that the handle part 14 may be maintained out of a reader's line of sight of the words indicated by the cursor part 15 during reading, particularly as the cursor part 15 is moved down the text. In FIG. 3 , one example of a suitable universal joint 18 is shown, in which the cursor part 15 has secured thereto a ball formation 19 , and the handle part 14 has an internal longitudinal part 21 terminating in a cup 22 . The cup 22 and ball formation 19 may be brought into tight engagement by moving the internal part 21 longitudinally relative to an outer handle part 25 , in the direction of the arrow A. This may be achieved by a screw connection between the internal part 21 and the outer handle part 25 , or by interengaging ratchets or otherwise.
Thus by tightening the engagement of the ball formation 19 and the cup 22 , the position of the cursor part 15 may be releasably fixed to the handle part 14 .
FIG. 4 shows a similar but opposite arrangement in which the cup 22 is provided on the cursor part 15 and a ball formation 19 is provided at the end of an internal part 21 of the handle part 14 .
FIG. 5 shows an alternative arrangement in which an internal part 21 of the handle part 14 terminates in a plurality of jaws 26 which may be closed about a ball configuration part 19 of the cursor part 15 , e.g. by actuating by rotation or longitudinal movement, an actuator within the internal part 21 of the handle part 14 .
FIG. 6 illustrates a universal joint arrangement 18 in which the handle part 14 has an integral ball formation 19 and the cursor part 15 has a recess formation 30 , the ball 19 and recess 30 formations being snap interengageable.
In the embodiments so far described with reference particularly to FIGS. 5 to 6 , because the cursor part 15 and handle part 14 are separable it will be appreciated that by providing a set of cursor parts 15 of different dimension (lengths) and configuration, a reading aid 12 suitable for a particular reader may be made up, or a reading aid 12 suitable for aiding reading of particular text, such as a column of a newspaper, in which case a cursor part 15 of a width corresponding to the width of the column may be selected.
FIG. 7 illustrates an arrangement in which the cursor part 15 is not separable from the handle part 14 , but the cursor part 15 includes a pair of wings 33 which may be folded from an outwardly extending condition for use, to the folded condition shown in which the wings 33 extend generally parallel to the handle part 14 . In this embodiment, at an end of the handle part 14 remote from the cursor part 15 , there is provided a writing point 34 of a writing implement such as a highlighter which is integrally provided within the handle part 14 .
In FIG. 8 , an alternative arrangement for including a writing implement is illustrated. In this arrangement, the handle part 14 has a main stem 35 which is grasped by a reader during reading, and a branch 36 which includes a writing implement 37 such as a highlighter with a writing point 34 . In the embodiment illustrated, the branch is pivotal relative to the main stem 35 about a pivot B so that the writing implement 37 may be folded alongside the main stem 35 , or into a recess of the stem 35 when not in use, or pivoted outwardly for use. In another arrangement the writing implement 37 may be provided in the main stem 35 and the cursor part 15 on the branch 36 . Such latter arrangement enables a user to exercise more control over the use of the writing implement 37 than where the writing implement 37 is provided on the branch 36 . In each case, instead of being pivoted, the branch 36 and main stem 35 may be relatively fixed.
FIGS. 9 and 10 illustrate an alternative embodiment of the invention, in which the cursor part 15 is connected to the handle part 14 by means of a joint 18 which would be universal, as illustrated in FIGS. 3 to 6 , were it not for the provision of a restraining part 38 , which restricts rotation of the handle part 14 about a longitudinal axis A of the handle part 14 . By virtue of the restraining part 38 , the user may more easily maintain the cursor parallel to lines of text when moving the reading aid 12 over a page.
The restraining part 38 is wire bent into a generally semi-circular configuration, which extends through an aperture 39 provided in the handle part 14 . The restraining part 38 is pivotally connected to the cursor part 15 , at a first 40 and second 41 end, by two attachment means 42 , 43 .
In order to engage with the attachment means 42 , 43 , the ends 40 , 41 of the restraining part 38 may be bent radially outwardly of the semi-circle formed by remainder of the restraining means 38 , as shown in FIG. 9 , or may be bent radially inwardly of the semi-circle, as shown in FIG. 10 . The universal joint 18 is located generally centrally between the two attachment means 42 , 43 , and generally at the centre of the semi-circle formed by the restraining part 38 .
The attachment means 42 , 43 are oriented with respect to the cursor part 15 such that the restraining part 38 may pivot about an axis parallel to a longitudinal axis of the cursor part is. The clearance between the handle part 15 and the restraining part 38 provided by the aperture 39 allows movement of the restraining part 38 within the aperture 39 , and therefore allows pivoting of the handle part 14 about the universal joint 18 with respect to the restraining part 38 . Thus, the restraining part 38 acts only to restrict rotation of the handle part 14 relative to the cursor part 15 about its longitudinal axis A.
In FIG. 11 , an alternative configuration of cursor part 15 is illustrated. In this embodiment the reading aid 12 is intended for use by a child, and the cursor part 15 is configured to resemble a paw print of a bear. The cursor part 15 may be configured to form any other image that may be popular with children, for examples, an animal, a cartoon character, or a football player. Such a cursor part configured to form a popular image may be used in any of the above embodiments of the invention.
If desired, a method of assisting reading may be performed on a computer by concurrently displaying with text on a display screen, a cursor to indicate a group of words in a line of text to be read. In such an arrangement, the cursor displayed may have a length greater than two words of average length of the text, but could also be shorter than this. The computer may be arranged to move the cursor relative to the text, or the cursor may be moved under the control of a reader. If desired, the speed of movement of the cursor relative to the text may be voice controlled, where the reader is reading out loud, or controlled using a pointing device such as a mouse.
The computer when in control, may move the cursor at an optimum speed for the reader's ability, and the speed may be changed as the reader's ability improves.
Thus the computer may be arranged to assess the reader's ability by the reader controlling the cursor movement during an assessment, either using a pointing device such as a mouse, trackball or the like, or by voice actuated control, and the computer being programmed to analyse the cursor speed and movement to determine the reader's ability.
The computer may be programmed to train the reader's eye movements, by increasing the speed of cursor movement as the reader's ability improves, and/or by moving the cursor over the whole text in a predetermined pattern designed to improve reading speed.
The size and configuration of the cursor may be changeable. In one arrangement, the cursor may simply underline the group of words being read at any instant. In a preferred arrangement, the cursor frames the word or group of words. If desired the text of the framed word or group of words may be highlighted by emboldening, enlarging or otherwise.
If desired, in highlighting a word or group of words, otherwise hidden text may be revealed.
These latter features are particularly helpful for use in reading text in cells of a spreadsheet.
The cursor may form an image which may appeal to children.
The features disclosed in the foregoing description, or the following claims, or the accompanying drawings, expressed in their specific forms or in terms of a means for performing the disclosed function, or a method or process for attaining the disclosed result, as appropriate, may, separately, or in any combination of such features, be utilised for realising the invention in diverse forms thereof. | A method of reading using a reading aid ( 12 ) including a handle part ( 14 ) which is adapted to be gripped manually at a location spaced from text to be read, and a cursor part ( 15 ) attached to the handle part ( 14 ) and extending transversely thereto, handle part ( 14 ) and the cursor part ( 15 ) being attached by a joint ( 18 ) which permits the handle part ( 14 ) to be moved relative to the cursor part ( 15 ) during reading, the cursor part ( 15 ) being positionable by manipulating the handle part ( 14 ) to indicate a part of a line of the text being read, the method including moving the cursor part ( 15 ) along the line and/or down the text during reading to indicate successive words or groups of words, whilst manipulating the handle part ( 14 ) relative to the cursor part ( 15 ) so that the handle part ( 14 ) is maintained out of the reader's line of sight whilst the cursor part ( 15 ) is maintained generally flat against the text. | 6 |
RELATED APPLICATIONS
This application claims priority to and is a continuation-in-part application of U.S. patent application Ser. No. 12/439,957, entitled Blade Assembly for Excavating Apparatus, Filed on Sep. 2, 2009, which is a national stage application of and claims priority to International Application No. PCT/AU2007/001297, filed Sep. 4, 2007, which designates the U.S., which application claims priority to Australian Application No. 2006904874, filed on Sep. 4, 2006. Each of the above-identified applications are expressly incorporated herein by this reference.
FIELD OF THE INVENTION
The present invention relates to a blade to be mounted to an excavating machine. Excavating machines comprise but not limited to bulldozers, tractor shovels, graders, drag line apparatuses and compacting machines.
In the context of the invention a blade is intended to cover any type of working tool with an edge which is intended to contact material so that it can be moved. Thus a blade includes but not limited to a bucket, collector and spreader.
By way of example the present invention will be described in relation to a bulldozer blade.
BACKGROUND OF THE INVENTION
A bulldozer can be used on a variety of working sites. The blade can be used for a variety of different operations including digging, carrying of soil or other material, banking, compacting and levelling. The design of the blade and how it is used determines the efficiency of the bulldozer in a working situation. It is advantageous to maximise working efficiency by designing a blade which is easier to use and can perform at least one function better than an existing blade.
The ability of a blade to dig into the ground depends on the shape of the front edge, force for pressing the blade into the ground as well as the angle of the blade when it contacts the earth. U.S. Pat. No. 6,938,701 discloses one type of bulldozer blade in which the front edge of the blade has a width which is larger than the width between the tracks of the bulldozer which carries it. This front edge is straight and perpendicular to the direction of movement of the vehicle in a forward direction. On either side of the central section the blade is angled rearwardly and then forwardly to provide three separate sections of cutting edges. The side and end sections are connected in a V-type configuration which is completely behind the front edge of the central section.
In operation the blade must be tilted downwardly with respect to its non-operative position in order to engage a ground surface.
The blade described in this patent suffers a number of drawbacks which reduces overall operating efficiency. One of the disadvantages with the blade design is that the blade must be tilted upwardly in order retain material effectively on its surface. Furthermore, the blade must be tilted downwardly to engage a ground surface. Furthermore, the ability of the blade to cut through a ground surface is inferior to blades which have a point. As well material which is contacted by the front edge moves up the front face of the blade but interferes with excavation of further material in front of the blade. Any material which moves to the side of the front edge of the blade generally escapes beyond each edge of the blade if the blade moves too far forward without being tilted upwardly.
Other disadvantages arise from the shape of the front face and difficulties associated with effectively cutting into a ground surface.
For existing bulldozers, present practices when loading material onto a blade that is tight is to use the corner tips to achieve penetration and roll the blade back when loaded. This has a tendency to turn the dozer towards the corner tip as the load is now off centre. If the operator is not very experienced he will use the steering clutches in an attempt to keep the dozer moving straight. As well the existing blades do not fill to full capacity when in operation.
OBJECT OF THE INVENTION
It is an object of the present invention to provide an alternate blade that overcomes at least in part one or more of the above mentioned disadvantages.
SUMMARY OF THE INVENTION
In one aspect the invention broadly resides in a blade for an excavating apparatus comprising
a substantially concave front face with a side wall on each side of the front face, said front face has a raised substantially concave centre section at a substantially central and lower position on the front face, said front face has a side gusset portion on each side of the centre section, side gusset portions slope from the centre section, said front face has a centre forward edge portion, a side forward edge portion on each side of the centre forward edge portion and an end forward edge portion on each distal side of the side forward edge portion;
wherein the angular position of the centre forward edge portion is discontinuous with the concave arc of the centre section and the concave arc of the centre section is discontinuous with the concave arc of a front face section above the centre section to form three adjacent discontinuous sections which cooperate with the side gusset portions to direct excavated material outwardly from the centre section towards the side walls.
Preferably the present invention provides a blade that can use its centre for penetration assisting the bulldozer's ability to use both tracks to push the blade and reduce the loading time then roll back after loaded.
Preferably a blade in accordance with the present invention has a centre for penetration which results in power being applied to the centre of the blade when loading and not the corners.
In one embodiment the end forward edge bottom edges are lower than the bottom edges of the side forward edges. The bottom corners of distal edges of the end forward edge are preferably the lowest point of the blade.
It is preferred that the angle β is less than θ where β is the angle between the end forward edge and a line perpendicular to the centre forward edge and θ is the angle between the side forward edge and a line perpendicular to the centre forward edge.
The centre forward edge preferably extends perpendicular to the forward direction of the blade.
Preferably the side forward edges are each angled rearwardly with respect to the centre forward edge.
At least one of the forward edge portions is attachable to the front face.
At least one of the forward edge portions is removably attachable to the front face or other part of the blade.
At least one forward edge is made separately from the rest of the blade.
The side edges may extend forward from either side of the front face.
According to one embodiment the side edges extend outwardly from either side of the front face.
Each forward edge may comprise a metal plate or plate of other impact resistant material.
Preferably the blade is described on the basis it is resting on a ground surface or in a neutral position.
According to one embodiment the end forward edge has a forward most end edge which is behind the centre front edge.
According to another aspect of the present invention there is provided a blade for an excavating apparatus comprising a front face, side walls on each side of the front face, a centre forward edge portion, a side forward edge portion at each side of the centre forward edge portion and an end forward edge portion at each distal side of the side forward edge portion; wherein each side wall has a front edge which is behind the forward most edge of the end forward edges and in front of the rearmost portion of the side forward edge portions.
Each side wall may have a lower edge portion which is slanted rearwardly.
The lower front edge of the side walls may be in front of the rearmost portion of the end forward edges.
Each upper portion of each side wall preferably extends over the end forward edges.
Each end forward edge may be disposed inwardly of an outer portion of each end forward edge.
It is preferred that each side wall has a front edge which is located behind the centre forward edge portion.
Preferably the rearmost point of the side forward edge portions is located behind the front edge of the side walls.
According to one embodiment the corner portion located between the end forward edges and the side forward edges is located behind the front edge of the side walls.
According to one embodiment the centre forward edge portion comprises a lower edge which extends rearwardly below the front face in a generally horizontal orientation.
According to another aspect of the present invention there is provided a blade for an excavating apparatus comprising a front face, side walls on each side of the front face, a centre forward edge portion on each side of the centre forward edge portion and an end forward edge portion on each distal side of the side forward edge portion;
wherein the front face comprises a substantially concave centre section and side gusset portion on each side thereof for directing material outwardly toward the side walls.
Preferably each gusset portion comprises a curved plate section curved towards respective side walls.
Each gusset portion may comprise a generally triangular surface portion.
Each centre section preferably has substantially the same width as the centre forward edge portion.
The centre section may be aligned behind the centre forward edge portion.
Each gusset portion may extend at a slant forwardly to an outer mid section of the side forward edge.
Preferably the front face is contoured so that material slides off it when the blade is oriented in a neutral position (tilted neither up or down).
Alternatively or in conjunction the front face is contoured so that the material slides off it when the side walls top edge is parallel to the ground.
According to one embodiment the width of the centre forward edge portion is less than the width between tracks of a vehicle or wheels of a vehicle to which the blade is connected/attached.
The blade may be adapted to be tilted forward and back/down and up.
Preferably the width W of the centre forward section is less than the width of the side forward edge portions M.
The width of the end forward edge portions is preferably less than the width of the side forward edge portions.
Preferably the width of the end forward edge portions is less than the width of the centre forward edge portion.
According to one embodiment of the invention the side walls are straight/vertical in a neutral position of the blade.
Preferably each optional feature of the invention can be used in any aspect of the invention.
Each edge may be inclined forward between 70° and 30° when the blade is in a neutral position.
Preferably the side forward edge is at an obtuse angle with respect to the centre forward edge.
According to one embodiment the blade is attached to a controlling machine through a lower pivot and an upper pivot connected to an actuable piston, which is adapted to tilt the blade upwardly or downwardly with respect to the lower pivot.
According to another aspect of the present invention each of the forward edge portions may be made separately as removably attachable plates.
It is preferred that the end forward edges have pointed lower end edges, which are configured to engage a ground surface before any part of the centre forward edge portion.
It is preferred that the front face comprises a concave surface from a lower end portion to an upper end portion.
Preferably the whole of the front face is concave.
According to one embodiment the front face comprises two concave portions, the lower concave portion being configured to allow retention of material thereon if the blade is tilted upwardly from its neutral position.
According to one aspect of the present invention anyone of the blades hereinbefore described is part of a blade assembly including attachment portions to enable the blade to be attached to an excavation apparatus such as a bulldozer, backhoe, or any other vehicle which utilises an excavation bucket.
It is to be understood that reference to “blade” is to be interpreted broadly to cover an excavation bucket, a digging implement which collects material and any other device which engages a ground surface or material deposited on a ground surface or equivalent and is able to cut or dig through the material and collect it on its upper surface.
According to another embodiment of the present invention there is provided a blade assembly comprising a blade according to any one of the above defined embodiments.
It is preferred that a blade assembly in accordance with one of the above defined embodiments includes one or more attachment portions for attachment to controlling rams for tilting the blade.
According to another embodiment of the present invention a blade according to any one of the previously described embodiments includes an attachment portion for attachment to a lifting ram.
According to a further embodiment of the present invention there is provided a blade assembly including a blade according to any one of the previously defined embodiments and an attachment portion which is configured to be attached to a lifting arm of a vehicle such as a bulldozer or grader.
According to another aspect of the present invention there is provided a method of controlling a blade according to any one aspect of the invention previously defined, the method comprising moving the blade downwardly, forcing the lowermost edge of the blade below a ground surface and tilting the blade upwardly while the lowermost edge is below the ground surface.
It is preferred that the lowermost edge comprises the centre forward edge portion.
Preferably the blade is tilted to a generally horizontal disposition.
It is preferred that the blade is tilted upwardly so front edges of the side walls are substantially in a vertical orientation.
According to another aspect of the present invention there is provided a controller for controlling operation of a blade assembly comprising a blade according to any one of the aspects of the invention previously defined, lifting pistons, tilting pistons and support arms, wherein the blade is able to be controlled by the pistons and support arms to engage a ground surface and roll back/tilt upwardly once the blade cuts into the ground surface.
According to a further aspect of the present invention there is provided a controller for controlling operation of a blade as defined in any one of the previous aspects of the present invention, the controller comprising a first module for controlling operation of tilting pistons, a second module for controlling lifting pistons and a third module for controlling blade support arms, wherein based on data relating to the material which is to be engaged by the blade, the first module is operated to control the lifting piston to drop the blade, the second module is operated to control the tilting piston to tilt the blade downwardly and wherein when the centre forward edge portion has cut into the ground surface/material module is operated to control the tilting piston to tilt the blade upwardly while maintaining the lowermost edge of the centre forward edge portion below the ground surface/material surface.
It is preferred that the third module maintains the blade in a substantially constant position relative to the ground surface. In this respect it is to be understood that the supporting arms are preferred to be in a horizontal disposition when the blade is tilted downwardly and the centre forward edge portion engages the ground surface/material.
According to the preferred embodiment of the present invention the support arms are pivotally connected to a rearward back portion of the blade through an attachment portion.
It is to be understood that the blade in accordance with one or more embodiments of the invention is connected to a machine such as a bulldozer through mountings including rams/pistons and supporting arms in a configuration consistent with conventional bulldozers.
According to one embodiment each module comprises a sub program of a computer program.
According to one embodiment of the present invention the controller includes one or more sensors for sensing the orientation of the blade.
According to another embodiment of the present invention each mounting (piston, arm, etc. includes a sensor for sensing the position/length of extension or contraction of a mounting.
According to one embodiment of the invention the tilting piston comprises a cylinder and rod and a position sensor for sensing the relative position of the rod and the cylinder.
According to another embodiment the lifting piston comprises a cylinder, rod and sensor for sensing the relative position of the rod and cylinder.
According to another embodiment of the present invention the support arms comprise a sensor for sensing the orientation of the arms with respect to a horizontal and/or vertical axis.
According to a further aspect of the present invention there is provided a method of controlling a blade in accordance with the present invention as defined in any one of the previous aspects, comprising collecting material on a front face of the blade, lifting the blade upwardly by operating the lifting pistons, tilting the blade upwardly by operating the tilting pistons whereby lowermost edges of the blade disengage from a ground surface.
It is preferred that the method includes moving the blade forward once it has disengaged from a ground surface.
In another aspect the invention broadly resides in a blade for an excavating apparatus comprising
a substantially concave front wall with a side wall on each side of the front wall, said front wall has a front face that has a raised substantially concave centre section at a substantially central and lower position on the front face, said front face has a side gusset portion on each side of the centre section, side gusset portions slope from the centre section, said front face has a centre forward edge portion, a side forward edge portion on each side of the centre forward edge portion and an end forward edge portion on each distal side of the side forward edge portion;
wherein the angular position of the centre forward edge portion is discontinuous with the concave arc of the centre section and the concave arc of the centre section is discontinuous with the concave arc of a front face section above the centre section to form three adjacent discontinuous sections which cooperate with the side gusset portions to direct excavated material outwardly from the centre section towards the side walls.
Preferably the side gusset portions extend from the centre section to the side forward edge portion adjacent the end forward position. Each side gusset portion preferably forms a substantially triangular shaped sloping section.
Preferably each of the side gusset portions extend from the centre section to a position where the side forward edge portion is adjacent to the end forward edge portion and forms a substantially triangular shaped sloping section either side of the centre section.
Preferably the centre forward edge portion and the side forward edge portions are substantially in line providing a substantially continuous edge portion.
Preferably the end forward edge portion is substantially in line with the side forward edge portion. Preferably the end forward edge portions provide a substantially continuous edge portion section with the side forward edge portions and the centre forward edge portion. Preferably the end forward edge portions are substantially aligned along a horizontal axis with the side forward edge portions and the centre forward edge portion.
In a preferred embodiment the centre forward edge portion is lower than the other edge portions so that it contacts the ground first and excavated material consequently moves up the centre forward edge portion and centre section.
In an alternate embodiment the end forward edge portion forms a v-shape with the adjacent side forward edge portion.
Preferably the end forward edge portions are substantially in line with the side forward edge portions and the centre forward edge portion and the centre forward edge portion is orientated lower than the other edge portions so that it contacts the ground first and excavated material consequently moves up the centre forward edge portion and centre section. Preferably the end forward edge portions provide a substantially continuous edge portion section with the side forward edge portions and the centre forward edge portion and the centre forward edge portion is orientated lower than the other edge portions so that it contacts the ground first and excavated material consequently moves up the centre forward edge portion and centre section. Preferably the end forward edge portions are substantially aligned along a horizontal axis with the side forward edge portions and the centre forward portion and the centre forward edge portion is disposed vertically lower than the end forward edge portions and the side forward edge portions.
Preferably a top section of the front wall adjacent the side walls curves over towards the front of the blade. Preferably the top section of the blade adjacent the side walls curves over by several degrees. Preferably the top section of the front wall adjacent the side walls bends towards the front of the blade by several degrees.
The side walls preferably extend higher than the front wall. More preferably the side walls extend higher and rearward of the front wall.
A corner formed by the front wall and the side wall is preferably supported by a bracket and without a boxed gusset.
A blade with an upper corner formed by the front wall and the side walls with the curved top section of the front wall and with the side walls that extend above the front wall preferably enables an increased volume of excavated material to be retained on the blade.
Preferably the top section of the blade has a plurality apertures for an operator to view in front of the blade. Preferably the plurality of apertures are spaced along a central and side sections of the top section of the blade.
Preferably there is an upper attachment point located on each of the side walls above and preferably behind the front face of the blade. Preferably the upper attachment point is used by cranes to lift the blade. The position of the upper attachment point is preferably a balanced position for a crane to lift the blade without swinging crooked.
Preferably there are a plurality of mountings on the back wall of the blade. The plurality of mountings preferably provides connection to one or more lifting arms and one or more rams. More preferably the plurality of mountings are positioned adjacent the back wall of the blade to have the centre of gravity of the blade closer to the associated vehicle thereby providing more control over the blade and helping balance the vehicle with the blade.
The attachment of the lifting arms and rams to the blade preferably orientates the blade in a manner so that substantially all of the carried excavated material can be discharged when the blade is in a forward tilt position.
The one or more rams attached to the mountings can preferably tilt the blade forward at an angle between 89 and 70 degrees relative to the ground level. Preferably the blade can tilt forward to a maximum of approximately 75.8 degrees relative to the ground level. Preferably the blade can tilt forward to an extent that allows the blade to unload substantially all of the carried excavated material.
The one or more rams attached to the mountings can preferably tilt the blade backwards at an angle between 91 and 100 degrees relative to the ground level. Preferably the blade can tilt backwards to a maximum of approximately 92.3 degrees relative to the ground level.
The degree of forward and rearward tilt is preferably achieved with rams that have longer piston strokes.
BRIEF DESCRIPTION OF THE DRAWINGS
Preferred embodiments of the present invention will now be described by way of example only with reference to the accompanying drawings in which:
FIG. 1 shows a diagrammatic plan view of a blade according to a first preferred embodiment of the present invention;
FIG. 2 shows a diagrammatic front view of the blade shown in FIG. 1 ;
FIG. 3 shows a diagrammatic cross-sectional side view of the blade shown in FIG. 1 ;
FIG. 4 shows another diagrammatic cross-sectional view of the blade shown in FIG. 1 ;
FIG. 5 shows a diagrammatic side view of the blade shown in FIG. 1 at cross section A;
FIG. 6 shows a diagrammatic side view of a bulldozer with a blade in accordance with the first preferred embodiment of the present invention in a neutral position;
FIG. 7 shows the bulldozer shown in FIG. 6 with the blade raised;
FIG. 8 shows the blade and bulldozer shown in FIG. 7 with the blade pitched forward;
FIG. 9 shows a bulldozer and blade in accordance with a first preferred embodiment of the invention on a horizontal ground surface;
FIG. 10 shows the bulldozer and blade shown in FIG. 9 with the blade tilted downwardly;
FIG. 11 shows the bulldozer and blade shown in FIG. 10 with the blade lowered below the horizontal ground surface;
FIG. 12 shows the bulldozer and blade shown in FIG. 9 moving down an inclined surface;
FIG. 13 shows the bulldozer and blade of FIG. 9 with the blade tilting upwardly prior to entering a second horizontal ground surface;
FIG. 14 shows the bulldozer and blade shown in FIG. 9 with the bulldozer about to enter the lower horizontal ground surface;
FIG. 15 shows the bulldozer and blade of FIG. 9 moving along a lower horizontal ground surface;
FIG. 16 shows a blade according to a first preferred embodiment of the invention attached to a bulldozer with the blade oriented downwardly to engage a horizontal ground surface;
FIG. 17 shows the blade and bulldozer of FIG. 16 with the blade tilted upwardly after engaging the ground surface;
FIG. 18 shows the bulldozer and blade of FIGS. 16 and 17 with the blade tilted upwardly and rolled back after collecting material in the blade;
FIG. 19 shows a diagrammatic view of a second preferred embodiment of the blade attached to a bulldozer wherein the blade is in a level position at ground level;
FIG. 20 shows diagrammatic view of a second preferred embodiment of the blade attached to a bulldozer wherein the blade is at full tilt back at ground level;
FIG. 21 shows a diagrammatic view of a second preferred embodiment of the blade attached to a bulldozer wherein the blade is at full tilt forward at ground level;
FIG. 22 shows a diagrammatic view of a second preferred embodiment of the blade attached to a bulldozer wherein the blade is at a full tilt forward at ground level on an incline;
FIG. 23 is a diagrammatic front view of a second preferred embodiment of the blade;
FIG. 24 is a diagrammatic front view of a second preferred embodiment of a section of the side of the blade marked C in FIG. 23 ;
FIG. 25 is a diagrammatic side view of a second preferred embodiment of the blade;
FIG. 26 is a diagrammatic view of a mounting portion of the blade marked K in FIG. 25 ;
FIG. 27 is a diagrammatic view of another mounting portion of the blade marked L in FIG. 25 ;
FIG. 28 is a diagrammatic front view of the blade similar to FIG. 23 ; and
FIG. 29 is a diagrammatic view of a side top section of the blade marked A in FIG. 28 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In accordance with the preferred embodiments of the present invention, a blade will be described that can use its centre forward edge for penetration. The blade attached to a bulldozer will be described and the ability to use the centre forward edge of the blade for penetration will assist the dozer's to use both tracks to push the blade and reduce the loading time and then roll back after being loaded.
FIGS. 1 to 18 show a first preferred embodiment of the blade whereas FIGS. 19 to 29 show a second preferred embodiment of the blade.
With reference to the first preferred embodiment of the blade, FIGS. 1 and 2 shows a blade 10 having a front face 11 , a centre edge 12 , middle edges 13 and 14 on either side of the centre edge 12 and end edges 15 and 16 on each end of the side edges 13 , 14 .
Each of the front edges 12 , 13 , 14 , 15 and 16 are preferably separately made from the rest of the blade and are removably attachable thereto. Thus in FIGS. 1 , 2 and 5 , there is a series of holes 17 which serve as attachment points.
Rearward of each edge 12 , 13 , 14 , 15 , and 16 , the front face 11 is specially shaped to enhance cutting by the blade as well as distribution of cut material away from the centre of the blade and furthermore retaining of excavated material on the blade when it is tilted upwardly from its cutting position.
The centre edge 12 of the blade extends rearwardly in a generally concave arc which preferably constitutes a rolled section of constant width and of the same width as the centre edge 12 . This rearward centre section 18 extends approximately half way along the front face 11 as shown in FIG. 4 . In FIG. 2 the central front section 18 appears rectangular.
It is preferred that the central front section 18 is a separately formed metal plate which is formed on the front face 11 .
Left and right side gussets 19 , 20 curve to each side from the left and right side 21 , 22 of the central front section 18 . In FIG. 2 these gussets 19 , 20 look triangular and extend forwardly from the rearmost end of the central front section 18 to middle blades 13 and 14 respectively to a point closer to their outer ends than their inner ends.
In effect both the central front section 18 and side gussets 19 and 20 appear as a raised section in the centre of the front face 11 .
The centre edge 12 is essentially straight and perpendicular to the direction of movement of the blade in the forward direction. Each of the middle edges 13 , 14 slant rearwardly at a angle of approximately 25° with respect to the centre edge 12 . Each of the middle edges 13 and 14 are approximately twice as long as the centre edge 12 and at their outer ends 22 , 23 form a V-shaped angle with the end edges 15 and 16 respectively.
The thickness of each of the front edges 12 to 16 is generally the same and each of them may be in the form of a metal plate.
The end edges 15 and 16 are angled forwardly and laterally from the middle edges 13 and 14 . They form an angle of approximately 110° with respect to each of the middle edges 13 , 14 .
As shown in FIG. 1 , each end edge 15 , 16 has a lower front corner 25 , 26 which is located behind the centre edge 12 . It is also noted that the front edge 27 , 28 of the end edges 15 , 16 are slanted slightly forwardly to form a slightly pointed corner 25 and 26 respectively.
As shown in FIG. 2 the horizontal level of the centre edge 12 and middle edges 13 and 14 is approximately the same. However the end edges 15 and 16 are angled slightly downwardly and forwardly from the ends 23 and 24 .
The front face 11 which is generally a concave shaped shovel has a general curvature on either side of the central front section 18 to each side 29 , 30 . These sides 29 , 30 are represented as vertical crease lines which form corner sections with outer wall sections 31 , 32 which extend laterally and forwardly at a similar angle to the end edges 15 and 16 with respect to the middle edges 13 and 14 . Side plates 33 and 34 extend from these walls 31 and 32 generally in a forward direction and thus perpendicular to the centre edge 12 .
The side walls 33 , 34 are typically in the form of large metal plates extending from the top of the front face 11 forwardly in a straight line then vertically downwardly to a slanted section 35 approximately three quarters of the length from the top corner edge 36 and inwardly to a point on the front face behind the end edges 15 , 16 .
As shown in FIG. 1 , front end 37 of the side walls 33 , 34 extend over part of the end edges 15 and 16 to a forward position approximately half way across them. The front edges 27 and 28 of the end edges 15 and 16 are the lateral most parts of the front face 11 and extend beyond the side walls 33 , 34 in a lateral direction. It is also noted that the corners 25 and 26 are both in front of and further to the side of the side walls 33 , 34 than their front edges 37 .
It is preferred that the overall concave curvature of the front face 11 with the raised central sections 18 , 19 and 20 is such that when the blade is connected to the bulldozer and is in a neutral position, that is it is not tilted forward or backward, any material on the front face of the blade is able to slide off it. Furthermore, only a slight tilting upwardly of the blade results in retention of a significant amount of material on the front face of the blade.
As shown in FIGS. 3 and 4 , the centre edge 12 and middle edges 13 and 14 are generally flat and straight. In FIG. 5 the rear face of the middle edge 14 is shown and this is also generally flat and straight and each of the edges appears as a thick metal plate.
Behind the blade 10 connection points 50 and 51 are provided at the lower end and close to the top end. The lower end is connected through a pivotal support part through connecting arms to a bulldozer and the point 51 is connected to a pivotal piston arm of the bulldozer. As a result tilting of the blade 10 occurs by movement of the piston and hence pivoting of the blade with respect to the connection point 50 .
A blade having the features described above when connected to a bulldozer is able to be tilted slightly downwardly so that the centre edge 12 is able to engage a ground surface or material on a ground surface. Initially the corners 25 and 26 of the end edges 15 and 16 contact the ground because they are lower. This also has the result that they wear more quickly than the centre edge and provide a barrier to help capture material within the confines of the blade.
As the blade moves forward, material moves up the centre edge 12 onto the central front section 18 and is distributed by side gussets 19 and 20 outwardly in a lateral direction. This directs material towards the side walls 33 , 34 . These walls act as a barrier which helps retain material within the confines of the blade. This retention is enhanced by the front edge 37 being located in front of the rearward edge of the end edges 15 and 16 .
Because the material is directed outwardly to the sides of the blade, cutting/grading by the centre edge 12 is enhanced because material is moved away from the central region. This movement to the sides may be enhanced by increasing the size of each of the gussets 19 and 20 and reducing the width of the section 11 . For example the section 11 may be made triangular with an apex at a rearward most point, thus having a triangular appearance with the apex of the triangle at a rearward point and the sides of the triangle leading into each of the gussets 19 , 20 .
Some of the noteworthy features of the first preferred embodiment include the following:
the centre cutting edges forward of the corner tips;
the centre cutting edge is at the same level as the corner tips when the blade is in the central or carry position;
the corner tips are lower than the centre cutting edge when the blade is in the central or carry position;
the centre cutting edge is lower than the corner tips when the blade is rotated forward or down into the digging position;
the centre cutting edge is higher than the corner tips when the blade is rotated back;
the blade has larger side plates to carry more material; and
the side plates are forward of the back edge of the corner tip.
When the blade is used on a dozer it provides the dozer with a number of operational features which are not available to dozers with existing blades.
Thus according to one embodiment, larger dozers with the blade according to the present invention have a function that allows the on board processor of the dozer to pitch the blade forward to dump material from the blade when the blade is raised past a preselected position. This function can be expanded to control the pitch of the blade when a digging operation is undertaken.
In accordance with the first preferred embodiment of the invention when the dozer is in the neutral position the cutting edges of the blades are all level with the ground except for the corner tips or outside cutting edges which may be lower. As shown in FIG. 6 the supporting arms 61 of dozer 60 are generally horizontal with tilting pistons 62 at approximately 45° with the control arms 61 and lifting pistons 63 also approximately at 45° with respect to the arms 61 . In this position the blade 64 is able to push material to a dump site. As shown the side plates 65 generally have their front edges 65 vertical and their top edges 66 horizontal.
After the blade 64 is raised by pivoting the arm 61 upwardly using the lifting piston 63 , as shown in FIG. 7 , the onboard processor may be operated to pitch the blade 64 forward as shown in FIG. 8 . This is achieved by operation of the tilting pistons 62 .
As shown in FIGS. 7 and 8 when the blade 64 is raised, edges 65 and 66 effectively pivot clockwise whereas in FIG. 8 they pivot anticlockwise. The result is the edges 65 and 66 are no longer in the vertical and horizontal disposition shown in FIG. 6 .
With the blade pitched forward, material collected on the blade is able to flow down from the blade and hence reduce any material from sticking to the blade and being carried back to the dig position.
It is preferred that the onboard processor is programmed for an autopitch step involving the raising and lowering of the blade as shown in FIGS. 7 and 8 . Alternatively an operator can perform these steps manually.
It is preferred that this function is part of a normal digging cycle involving loading, dumping and clearing/dislodging material on the blade.
According to one embodiment it may be an advantage to set the dig or pitch forward auto operation in an aggressive setting for hard material. This would start the pitching of the blade when the blade is lowered a short distance from the neutral position. It may also be an advantage to set the auto pitch in a less aggressive setting when digging softer material. This less aggressive setting would allow the blade to be lowered a larger distance from the neutral position before the blade is pitched forward.
The dump auto settings may be set in the same manner outlined above.
In the operation described above a bulldozer is able to be used to push material to a dump site. According to another operational task a bulldozer may be required to operate on a downwardly or upwardly inclined slope. FIGS. 9 , 10 , 11 , 12 , 13 , 14 and 15 show how a bulldozer with a bucket according to the first preferred embodiment may be operated so as to control the orientation of the bucket as the bulldozer moves forward. Thus as shown in FIG. 9 , the bulldozer 70 with a bucket 71 is operated so that the onboard processor uses the auto pitch feature to follow the contour of the ground surface. Thus in FIG. 10 the blade 71 is pitched/tilted forwardly using tilting pistons 72 after a slight lifting of the blade 71 by operation of arms 73 and lifting pistons 74 .
In FIG. 11 the bulldozer 70 moves forward and the blade moves downwardly first under operation of pistons 74 and 72 and arms 73 . As a result the blade 71 has an initial forward pitch as the dozer starts to dig and after the dozer follows the blade into the inclined area as shown in FIG. 12 , the blade is returned to its neutral position again by operation of pistons 72 to 74 and arms 73 .
After the dozer is following the incline downwardly, the blade 71 is loaded with material and the blade is then required to pitch backwardly so that the dozer can start pushing the material to the dump site.
Thus in FIGS. 13 and 14 it is shown how operation of pistons 72 and 74 results in an upward tilt of blade 71 as the dozer moves from the incline to the flat surface and then once on the flat surface or as the dozer completes movement to the flat surface, the blade is again tilted back to the neutral position as shown in FIG. 15 .
Although the example given above relates to movement of the dozer from a level to a downwardly inclined slope and back to a level surface, the operations involved with regard to movement of piston arms and blade 71 are simply reversed if the dozer moves in the opposite direction. As a result it is clear that there are movements of the blade which are effectively repeated and can be stored in the data processor for automated operation depending upon the type of terrain on which the dozer is to work. Thus the onboard data processor or even a remote data processor which has information relayed to it from the bulldozer can be programmed to tilt the blade in accordance with the operation shown in FIGS. 9 to 11 to the neutral position shown in FIG. 12 and then again tilt the blade in the manner shown and described in relation to FIGS. 13 and 14 with the result that it again ends in the neutral position as shown in FIG. 15 . For an upwardly inclining movement of the bulldozer the tilting movement of the blade is simply reversed.
It is to be understood that tilting of the blade is controlled by the tilting and lift pistons and the control arms of the bulldozer. Accordingly a data processor effectively through sensors located on each of these components can determine the orientation of the blade and can automatically control these components to tilt the blade as the bulldozer moves. Likewise sensors can be located on the blade.
In accordance with another mode of operation of a dozer utilising the blade of the preferred embodiment of the invention, it is noted that if the blade 81 as shown in FIG. 16 is tilted forwardly to cut into a ground surface there is a tendency because of the design of the blade to cut deeper into the ground surface. This causes the blades cutting edges and/or corner tips to dip lower than the ground level and adjustments need to be made with the lift mechanism to keep the blade at the same height. Accordingly it is preferable that after the forwardmost cutting edges of the blade cut into the ground, there is a rollback operation involving tilting the blade upwardly as shown in FIG. 17 back to a neutral position. As shown in FIG. 18 a final slight tilting upwardly can be initiated to collect material on to the blade and enable it to be carried to a dumping location.
The data processor can be programmed to operate the lifting and tilting pistons in conjunction with the supporting arms to initially tilt the blade 81 forward so that the forward most edge cuts into a ground surface and then to operate these components to tilt the blade 81 to a neutral position so the bottom edge of the front edge of the blade is able to travel in a horizontal orientation. Finally material collected within the confines of the blade 81 is able to be transferred to another location by a slight further tilting of the blade upwardly so that the forward most edge of the blade is not engaging with the ground surface.
Alternatively a data processor on board the bulldozer or remote from the bulldozer is programmed to adjust the blade to keep the nominated cutting edges or corner tips at a constant height. The actual height selected will be dependent upon a number of factors such as the hardness of the ground surface, the size of the bucket, the size of the dozer, the angle of the ground surface etc.
The use of the blade reduces the dependency of the steering clutches and brakes to keep a bulldozer moving straight when loading the blade. As the majority of the load will be centrally located on the blade, the operator has comparatively improved steering and a greater control of the blade.
FIGS. 19 to 29 describe a second embodiment of the blade. With reference to FIGS. 19 to 22 , blade 100 is attached to dozer 101 . The lifting arms 102 of the dozer 101 are attached to arm mountings 103 on the back of the blade 100 . Horizontal rams 104 and vertical rams 109 of the dozer 101 are attached to ram mountings 105 on the back of the blade 100 . The arm mountings 103 and ram mountings 105 are described more fully with reference to FIGS. 25 , 26 and 27 . The arm mountings 103 and ram mountings 105 are located adjacent the back wall 107 of the blade 100 thereby positioning the blade 100 as close as possible to the dozer 101 . By reducing the space between the dozer 101 and blade 100 , the centre of gravity is brought back towards the dozer 101 and consequently provides the dozer 101 with a comparatively greater control and balance when using the blade 100 . As a consequence of the attachment of the blade 100 to the lifting arms 102 , horizontal rams 104 and vertical rams 109 , the orientation of the blade 100 is such that there is approximately 43 degrees between an axis formed between the forward edge portions 110 and the forward edge portions 110 and the mounting 105 that connects with the horizontal rams 104 when the forward edge portions 110 are in a level position at ground level.
With reference to FIG. 20 , the blade 100 can be tilted back approximately 92.3 degrees between the blade 100 and the ground level when in a level position at ground level. The degree of backward tilt enables the carried excavated material to be retained on the blade 100 .
With reference to FIG. 21 , the blade 100 can be tilted forward approximately 75.8 degrees between the blade 100 and the ground level when in a level position at ground level. The degree of forward tilt enables substantially all of the carried excavated material to be discharged from the blade 100 .
With reference to FIG. 22 , the blade 100 can be tilted forward at approximately 43 degrees when moving along and incline with a gradient of 14 degrees.
With reference to FIGS. 23 and 24 , the blade 100 has forward edge portions 110 , side walls 111 and front wall 112 . The forward edge portions 110 include centre forward edge portion 115 , side forward edge portions 116 and end forward edge portions 117 . The forward edge portions 110 are substantially aligned in a horizontal axis with the centre forward edge portion 115 inclined downwardly relative to the side forward edge portions 116 and end forward edge portions 117 .
The front wall 112 generally has a concave shape. The front wall 112 has a raised substantially concave centre section 119 . The centre section 119 has a substantially central and low position on the front wall 112 . The angular position of the centre forward edge portion 115 is different to the concave arc of the centre section 119 which is different to the arc of the concave front wall 112 above the centre section 119 . There is a discontinuity in the shape of the front face from the centre forward edge portion 115 through the centre section 119 to the front wall 112 above the centre section 119 .
On either side of the centre section 119 there is a side gusset portion 121 that slope downwardly from the centre section 119 to the outer sections of the front wall 112 . Each of the side gusset portions 121 extends from the raised centre section 119 to the side forward edge portions 116 adjacent the end forward end portions 117 .
Material such as dirt is picked up by the centre forward edge portion 115 , moved towards the centre section 119 and directed outwardly from the centre section 119 via the side gusset portions 121 towards the side walls 111 .
The top section 123 of the front wall 112 is curved or bent over towards the front wall 112 by a few degrees to maintain a concave shape and assist in retaining excavated material. The side walls 111 extend above the top of the front wall 112 and cooperate with the front wall 112 to retain excavated material. The bracket 124 is positioned between the top section 123 and the side walls 111 to strengthen the integrity of the blade 100 . There is an attachment point 125 on the side wall 111 positioned above and behind the front wall 112 . The position of the attachment point 125 above and behind the front wall 112 enables a crane to lift the blade 100 without being unbalanced and swinging crookedly.
In the first preferred embodiment, there is shown a boxed gusset in the corner formed between the side wall and the front wall. In the second preferred embodiment, there is no need for the boxed gusset as the side wall 111 extends above the front wall 112 and the attachment point 125 for lifting the blade 100 is above and behind the front wall 112 .
With reference to FIGS. 25 , 26 and 27 , mountings 103 and 105 located on the back face 132 of the blade 100 allow attachment of lifting arms 102 and rams 104 , 109 respectively. The mountings 103 , 105 are located close to the back face 132 in order that the centre of gravity is moved back towards the dozer 101 thereby providing the dozer 101 with greater control and balance with respect to operation of the blade 100 .
With reference to FIGS. 28 and 29 , there is shown apertures 127 in the top section 123 . These apertures 127 are located in the centre and sides of the top section 123 . These apertures 127 provide the operator with a view of what is in front of the blade 100 . The second preferred embodiment has apertures 127 on both sides of the top section 123 .
It is to be understood that, if any prior art publication is referred to herein, such reference does not constitute an admission that the publication forms a part of the common general knowledge in the art, in Australia or in any other country.
In the claims which follow and in the preceding description of the invention, except where the context requires otherwise due to express language or necessary implication, the word “comprise” or variations such as “comprises” or “comprising” is used in an inclusive sense, i.e. to specify the presence of the stated features but not to preclude the presence or addition of further features in various embodiments of the invention. | An improved blade assembly for an excavating apparatus having a front wall with a raised concave center section with sloping side gussets on each side of the center section for directing excavated material from the center to the side of the blade is described. There are improvements to the side gussets to further assist in directing excavated material, improvements to the shape of the front wall of the blade to retain excavated material and improved mountings to the dozer to improve blade control and balance and discharging of excavated material. | 4 |
This invention relates to a gear drive or transmission. It relates especially to such a gear drive or transmission with a continuously variable input/output drive ratio.
BACKGROUND OF THE INVENTION
1. Field of the Invention
A gear drive or transmission is often interposed between the motor and a driven device such as a rotor, shaft, wheel, etc. so that the device will rotate at a lower speed with higher torque than the motor shaft, or vice versa. A variable speed gear drive has a plurality of gears or gear sets which can be selectively interposed between the input and output shafts of the gear drive so as to change the gear or drive ratio of the drive.
2. Description of the Prior Art
There do exist in the prior art transmissions which have a continuously variable input/output drive ratio. Usually these have a first rotary member which is conical and a cylindrical rotary member, the two members being coupled together by an endless belt loop encircling the members. The torque applied to one member is coupled via the belt to the other member. The speed ratio may be changed by shifting the belt along the length of the conical member. In other words, if the conical member is rotated at a selected speed and the belt is located at the larger diameter end of the conical member, the other member will rotate at a relatively high speed. On the other hand, if the belt is located at the small diameter end of the conical member, the other member will rotate at a lower speed, the speed ratio being dependent upon the cone angle of the conical member.
Such transmissions employing belts are disadvantaged, however, in that there is slippage between the belt loop and the driving and driven members. Also the belt loop may stretch when under load. Consequently there is not a positive transmission of power between the driving and driven members.
In order to avoid the aforesaid problems, attempts have been made to construct transmissions or gear drives whose driving and driven members comprise gears whose teeth mesh to transmit power from the driving to the driven member. As shown in U.S. Pat. Nos. 5,608,390; 5,653,143 and 6,321,613, for example, the transmission may include a rotary conical gear member composed of a series of separate conical sections supported by rotary shaft and a second member in the form of a pinion slidably mounted to a second rotary shaft positioned alongside the conical gear member. The spur gear is rotatably coupled to the second shaft but slidable therealong so that the pinion can be positioned opposite any one of the conical sections making up the conical member so as to vary the input/output drive ratio of the transmission.
Such nominally continuously variable speed gear drives have a problem in that when the pinion is moved along its shaft to change the gear ratio of the transmission, it is momentarily disposed opposite two sections of the conical member at the same time. Since those sections have different diameters, they also have different numbers of teeth. Therefore, rather elaborate steps have to be taken to enable the pinion to mesh properly with the conical gear member at all positions of the pinion. Usually this involves providing a certain amount of rotary play between the various conical sections making up the conical gear member and coupling those sections to their common shaft by means of clutches. In other such drives, the conical gear sections making up the conical gear member are stepped along their diameters and provided with specially shaped teeth. Those attempted solutions devised to enable changing the drive ratio of such transmissions result in machines which are overly complex and costly. Furthermore, such transmissions do not really have a continuously variable drive ratio because the pinion cannot be left opposite two conical sections of the conical gear member at once for too long a time without causing excessive wear of the gear teeth and greatly increasing the likelihood that the transmission will freeze up or jam.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide an improved variable ratio gear drive or transmission for transferring torque between an input shaft and an output shaft.
Another object of the invention is to provide a transmission of this type whose drive ratio is truly continuously variable over the entire operating range of the transmission.
Another object of the invention is to provide such a gear drive which is less complex than prior comparable variable ratio positive drive transmissions of this general type.
Other objects will, in part, be obvious and will, in part, appear hereinafter.
The invention accordingly comprises the features of construction, combination of elements and arrangement of parts which will be exemplified in the following detailed description, and the scope of the invention will be indicated in the claims.
Briefly, my transmission comprises a first rotary shaft which carries a continuous coaxial helical toothed rack whose diameter progressively increases along the shaft. Positioned parallel to the toothed surface of the rack as a second rotary shaft which carries a pinion whose teeth mesh with those of the rack. The pinion is rotatably coupled to its shaft but slidable therealong so that its teeth can mesh with those of the rack at any location along the length of the rack.
The drive ratio of the transmission may be changed by sliding the pinion along its shaft by hand or by other suitable means such as a linear actuator, lead screw drive, piston, etc. Either one of the two shafts may function as the driving or input member, the other shaft then being the driven or output member. In either event, since the slidable pinion may remain in driving engagement with the rack at any point along the length of the rack, the transmission does have a drive ratio which is truly continuously variable over the entire operating range of the transmission.
Since the helical rack is a single continuous member, it may be connected directly to its shaft without the imposition of clutches and other such devices that are found in prior gear drives whose conical gear members are composed of a series of separate conical gear sections.
BRIEF DESCRIPTION OF THE DRAWINGS
For a fuller understanding of the nature and objects of the invention, reference should be made to the following detailed description taken in connection with the accompanying drawings, in which:
FIG. 1 is a sectional view with parts in elevation of a variable ratio transmission incorporating the invention;
FIG. 2 is a diagrammatic view illustrating the operation of the FIG. 1 transmission;
FIG. 3 is an elevational view with parts in section, on a larger scale, showing a portion of the FIG. 1 transmission, and
FIGS. 4A and 4B are sectional views taken along lines 4 A— 4 A and 4 B— 4 B, respectively, of FIG. 3 .
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1 of the drawings, my transmission comprises a housing or support 10 having opposite walls 10 a and 10 b containing bearing units 12 and 14 , respectively, for rotatably supporting the opposite ends of a shaft 16 . Shaft 16 is mounted to a continuous rack 18 which is wound about the shaft so that it has many spaced apart convolutions 18 a . The rack 18 has a conical profile in that the diameters of its convolutions 18 a progressively increase along the length of shaft 16 as though the rack 18 were spirally wound about a conical envelope 20 as shown in phantom in FIG. 2 . Conical envelope 20 may be real, i.e. a conical segment of shaft 16 as shown in FIG. 1, or it may be in imaginary in which case the convolutions 18 a may be connected to shaft 16 by a multiplicity of different-length spokes 22 extending out from shaft 16 to the convolutions 18 a at spaced-apart locations along the rack. In both cases, the teeth of the rack convolutions 18 a face away from shaft 16 and are more or less parallel to the axis of the shaft. On the other hand, they could face toward the shaft axis.
The transmission depicted in FIG. 1 also includes a second shaft 26 which is spaced parallel to the conical surface of envelope 20 . The opposite ends of shaft 26 are rotatably supported by bearing units 28 and 30 in the housing walls 10 a and 10 b , respectively. Shaft 26 has one or more splines 26 a and supports a gear member shown generally at 32 which is rotatably coupled to, but slidable along, shaft 26 so that the teeth of gear member 32 can mesh with those of rack convolutions 18 a at any location along the rack.
Either one of the shafts 16 and 26 may be the input or output of the transmission, i.e. either the driving or driven shaft. Although not necessary, to enable the input and output shafts of the transmission to be co-linear, one end of shaft 26 may be provided with a cone gear 36 which meshes with a second cone gear 38 at the end of a third shaft 42 rotatably mounted by means of a bearing unit 44 in a housing or support wall 10 c so that the shaft 42 rotates about the same axis as shaft 16 . Thus the transmission is completely reversible and either the shaft 16 or the shaft 42 may be the driving member of the transmission, the other shaft then being the driven member.
Still referring to FIG. 1, gear member 32 may be slid along its shaft 26 by means of a slider shown generally at 52 . In the illustrated embodiment of the transmission, slider 52 comprises a carriage 54 connected to the gear member 32 by an arm 54 a and which travels along a lead screw 56 . Screw 56 has one end rotatably supported by a bearing unit 58 in housing or support wall 10 a and its opposite end connected to the shaft 58 a of a reversible step motor 58 mounted to housing or support wall 10 c . When the shaft 58 a is rotated in one direction or the other, the gear member 32 is moved in one direction or the other along the shaft 26 and thus meshes with different convolutions of the rack 18 , to vary the drive ratio of the transmission. Since the rack 18 is a single continuous member, the gear member 32 can be positioned at any location along the rack so that the drive ratio of the transmission is truly continuously variable as the member 32 is moved between the larger diameter end of rack 18 and the smaller diameter end thereof. Of course, any other conventional actuator maybe used to move the gear member along its shaft.
Refer now to FIG. 3 which shows the gear member 32 in greater detail. It comprises a sleeve 62 whose inner surface is slotted to receive the spline(s) 26 a of shaft 26 . Thus the sleeve 62 is rotatably fixed to, but slidable along, shaft 26 . Relatively loosely encircling sleeve 62 is at least one pinion, 64 a . The at least one pinion 64 a is captured on the sleeve by sleeve end flanges 62 a and 62 b . As best seen in FIG. 2, the teeth of pinion 64 a mesh with those of the helical rack 18 . Depending upon the spacing X of the convolutions 18 a , the gear member 32 may have a single, pinion 64 a rotatably fixed to sleeve 62 and thus to shaft 26 or member 32 may include an additional pinion 64 b on sleeve 62 next to pinion 64 a.
More particularly, if the spacing X is small and rack 18 has a relatively small cone angle, the teeth of adjacent convolutions 18 a are offset only slightly relative to one another. Therefore, a single pinion 64 a may be used whose width Y is at least somewhat greater than X and whose teeth are formed so as to have a somewhat loose fit with those of rack 18 .
On the other hand, for larger convolution spacings X and larger rack cone angles, gear member 32 may include a second pinion 64 b as shown wherein the combined widths Y and Z, respectively, of the two pinions should be greater then X, with both pinions having teeth which mesh normally with those of the rack.
If the gear member 32 does have two pinions 64 a , 64 b , the pinions are preferably formed so as to be rotatable on the sleeve 62 and relative to one another to an angular extent comparable to at least one gear tooth in either direction. For this, as shown in FIGS. 3, 4 A and 4 B, sleeve 62 is formed with a radially outwardly extending key 66 which projects into an arcuate recess 68 in the face of pinion 64 a which is opposite pinion 64 b . That same key 66 also projects into a similar arcuate recess 72 in pinion 64 b that recess being disposed directly opposite recess 68 . Preferably, springs 74 are provided in one of the recesses, say recess 72 , in order to bias the corresponding gear 64 a to a neutral angular position on sleeve 62 (and shaft 26 ) when it is not engaged to the helical rack 18 , i.e. when it is positioned between convolutions 18 a.
Also as best seen in FIGS. 4A and 4B, one of the pinions, i.e. pinion 64 a , is provided with a spring-loaded ball 78 which projects into an arcuate groove 82 in the counterfacing surface of the other pinion 64 b . The bottom wall 82 a of groove 82 is sloped so that it is deeper at the center of the groove than at the ends thereof. Thus, the wedging effect of the spring-loaded ball 78 in the groove 82 angularly biases pinion 64 b to a home position wherein its teeth are in alignment with those of pinion 64 a.
During operation of the transmission, when one of the shafts 16 or 42 is rotated by suitable motive means (not shown), the other shaft 42 or 16 will rotate at a speed determined by the setting of the gear member 32 along the helical rack 18 . Normally for a given speed, gear member 32 is set so that it is centered on a selected rack convolution 18 a . When changing speed that member is moved to or over an adjacent convolution. During that change, one of the pinions 64 a , 64 b , i.e. the leading pinion, will disengage from the selected convolution 18 a and engage the adjacent convolution, while the other, trailing, pinion remains meshed momentarily with the selected convolution. The small misalignment of the corresponding teeth of the two adjacent rack convolutions will be accommodated by a small angular offsetting of the two pinions 64 a and 64 b until the trailing pinion disengages from the selected convolution, at which point the two pinions will return to their home position on sleeve 62 as the gear member 32 is centered on the adjacent convolution 18 a . Since the rack is rotating, the gear member can move easily from one convolution to the next with the pinions 64 a and 64 b meshing with two adjacent convolutions 18 a , 18 a at the same time while being biased to a home position related to shaft 26 and to each other.
Since the rack 18 is continuous and wound in a helix or spiral, the gear member 32 can be set at any location along the rack and remain there, even if it engages two convolutions 18 at once, without causing wear of the gear teeth or jamming of the transmission. In other words, there are no indeterminate positions of the gear member 32 as is the case with prior comparable transmissions employing a conical gear composed of individual gear sections.
It will thus be seen that the objects set forth above among those made apparent from the preceding description are efficiently attained. Also, since certain changes may be made in the above construction without departing from the scope of the invention, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.
It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention described herein. | A continuously variable drive ratio transmission includes a support, a first shaft rotatably mounted to the support so that shaft can rotate about a first axis, a helical rack supported by the first shaft so that the rack has a plurality of toothed convolutions facing away from and spaced apart along the first shaft, the diameters of said convolutions being such that together they define a conical envelope encircling the first shaft. A second shaft is rotatably mounted to the support so that the second shaft is spaced from and extends parallel to the envelope, and a gear member is mounted to the second shaft for rotation therewith, the gear member having teeth which mesh with those of the rack. The gear member is slidable along the second shaft so that the gear member may be positioned at any location along the rack. | 5 |
BACKGROUND
[0001] 1. Field of Invention
[0002] The present invention relates generally to hospital gowns and more specifically to gowns with specific pockets, slits to allow for maximum mobility of patient with various monitors, catheters and lumens attached and closures that are simple to use and provide for patient privacy.
[0003] 2. Prior Art
[0004] The basic requirements for hospital gowns are ease of access to various areas of the patients body for examination or treatment purposes by the medical professionals involved; a sterile garment to provide coverage of the patient during examination, hospital stay or surgery; and minimum coverage for protection of patient modesty. Various attempts have been made to improve the design of hospital gowns in these areas with some attention to improving the ease of dressing the patient in such garments but with little attention to the convenience and mobility of the patient.
SUMMARY OF THE INVENTION
[0005] An object of the multi-purpose hospital gown is to cover the patient's body for personal modesty without an over garment for ambulation to the bathroom or the hallways for other purposes.
[0006] Another object of the multi-purpose hospital gown is to allow for ease in dressing a patient either by the patient or with the help of an attendant.
[0007] Another object of the multi-purpose hospital gown is to provide a gown that is economical to manufacture and maintain.
[0008] Another object is to provide a multi-purpose hospital gown that is constructed in such a manner as to enable easy access to either the patient's front or back area.
[0009] Another object is to provide a multi-purpose hospital gown that is constructed with a telemetry pocket in the upper frontal area with a slot in the back for passage of the telemetry wires to the patient.
[0010] Another object is to provide a multi-purpose hospital gown that is constructed with additional pockets on the lower frontal area for such items as J. P. Drains, Hema Vacs, and On-Q Pumps with slots in the gown to allow for passage of connecting apparatus.
[0011] Another object is to provide a multi-purpose hospital gown that is constructed with slits on the lower right frontal area that are used for hooking a catheter bag on the inside of the gown allowing the patient to ambulate with the bag concealed.
[0012] Another object is to provide a multi-purpose hospital gown that is constructed with releasable connections on the upper seams of the sleeves.
[0013] Still further objects and advantages will become apparent from a consideration of the ensuing description and accompanying drawings. In the description, reference is made to the accompanying drawings which form a part thereof, and in which are shown, by way of illustration, specific embodiments in which the invention may be practiced. These embodiments will be described in sufficient detail to enable those skilled in the art to practice this invention, and be understood that other embodiments may be utilized and that structural changes may be made without departing from the scope of the invention. In the accompanying drawings, like reference characters designate the same or similar parts throughout the several views.
DRAWINGS
[0014] The invention is described with reference to the following drawings:
[0015] FIG. 1 is a front view of the outside surface of a Multi-purpose Hospital Gown body assembly;
[0016] FIG. 2 is a rear view of the inside surface of a body assembly;
[0017] FIG. 3 is an inside view of right sleeve front;
[0018] FIG. 4 is an inside view of right sleeve back;
[0019] FIG. 5 is an inside view of left sleeve front;
[0020] FIG. 6 is an inside view of left sleeve back;
[0021] FIG. 7 is an assembled view of right sleeve;
[0022] FIG. 7A is an assembled view of left sleeve;
[0023] FIG. 8 is a perspective front view of gown as worn; and
[0024] FIG. 9 is a perspective rear view of partially opened gown.
REFERENCE NUMBERS
[0000]
10 -Multi-purpose Hospital Gown
11 -body assembly
12 -body outside surface
13 -body inside surface
14 -waist rear tie strap
16 -right neck tie strap
18 -left neck tie strap
20 -lower left pocket
22 -telemetry pocket slot
24 -lower right pocket
26 -lower catheter bag slit
28 -upper catheter bag slit
29 -right sleeve assembly
30 -body edge right sleeve rear
31 -body to right sleeve rear seam
32 -body edge right sleeve front
33 -body to right sleeve rear seam
34 -neck front
35 -left sleeve assembly
36 -body edge left sleeve front
37 -body to left sleeve from seam
38 -body edge left sleeve rear
39 -body to left sleeve rear seam
40 -lower right pocket slot
41 -neck side right sleeve front
42 -lower left pocket slot
43 -neck side right sleeve rear
44 -telemetry pocket
45 -neck side left sleeve front
46 -waist front tie strap
47 -neck side left sleeve rear
48 -right sleeve front
50 -right sleeve rear
52 -left sleeve front
54 -left sleeve rear
56 -right sleeve front separable edge
58 -right sleeve front open end edge
59 -right sleeve front bottom edge
60 -right sleeve bottom seam
61 -right sleeve rear bottom edge
62 -right sleeve rear open end edge
64 -right sleeve rear separable edge
66 -female snap fastener
68 -male snap fastener
70 -right sleeve front edge
72 -right sleeve rear edge
74 -left sleeve front edge
76 -left sleeve rear edge
78 -left sleeve front open end edge
79 -left sleeve front bottom edge
80 -left sleeve bottom seam
81 -left sleeve rear bottom edge
82 -left sleeve rear open end edge
84 -left sleeve rear separable edge
86 -left sleeve front separable edge
88 -body right side
90 -body left side
92 -body bottom edge
94 -right end under arm clearance angle
95 -right arm pit
96 -body right top
97 -left arm pit
98 -body left top
99 -body frontal area
DESCRIPTION
[0089] In order that the invention is fully understood it will now be described by way of the following examples in which Multi-purpose Hospital Gown 10 is shown in FIGS. 1-9 .
[0090] Turning to FIGS. 1 and 2 , body assembly 11 is disclosed. Body 11 is preferably constructed of soft, washable material and is approximately 72 inches wide and 44 inches tall. These exemplary dimensions are for an average adult gown although it is understood that the dimensions for the various pattern pieces could easily be altered for several different body sizes and shapes. FIG. 1 shows lower right pocket slot 40 and lower left pocket slot 42 cut through body assembly 11 approximately 5 inches wide, providing access into pockets 24 and 20 respectively and through the tops of pockets 24 and 20 to the patient's body for apparatus attachment. Pockets 24 and 20 may be formed by sewing 6¾ inch material squares to body inside surface 13 with their bottom edges approximately 18 inches above body bottom edge 92 , directly below the center of neck front 34 , approximately 3 inches apart. Pockets 24 and 20 are designed to retain J. P. Drains, Hema Vacs, and On-Q Pumps or personal items if not required for a particular medical device. FIG. 2 shows left bottom pocket 20 and right bottom pocket 24 sewed to body inside surface 13 .
[0091] Telemetry pocket 44 may be formed by sewing a 6½ inch tall by 5½ inch wide patch of material to body outside surface 12 with its bottom edge approximately 25 inches above body bottom edge 92 , centered under neck front 34 . FIG. 2 shows telemetry pocket slot 22 cut through body assembly 11 , directly behind Pocket 44 where pocket 44 is designed to retain most on-body monitoring telemetry units and slot 22 is provided for connection of monitoring apparatus to the patient's body.
[0092] Right neck tie strap 16 and left neck tie strap 18 are attached to the upper ends of body assembly 11 at body right top 96 and body left top 98 respectively. Straps 16 and 18 are approximately 15 inches long as shown in both FIGS. 1 and 2 . When tie straps 16 and 18 are tied together they form the closure means for the neck region of Multi-purpose hospital Gown 10 . Waist rear tie strap 14 extends away from body right side 88 approximately 15 inches in length and is attached at the base of right end under arm clearance angle 94 , approximately 29 inches above body bottom edge 92 . Waist front tie strap 46 is attached to body outside surface 12 approximately 29 inches above body bottom edge 92 , approximately 18 inches from body left side 90 . When tie straps 14 and 46 are tied together they form a closure means at waist level for the wrap around design of Multi-purpose Hospital gown 10 . Alternative closure means such as hooks and eyes, snaps or Velcro type fasteners are also contemplated as part of this invention.
[0093] FIG. 1 also shows two approximately 2 inch long slots 26 and 28 with their bottoms positioned approximately 8½ an 15 inches from body bottom edge 92 , with their centerlines approximately 32½ inches from body right side 88 . Slots 26 and 28 are used for hooking a Foley Catheter bag (not part of this invention) on the inside of Multi-purpose Hospital Gown 10 providing privacy for patients so encumbered during required ambulation.
[0094] FIGS. 3 , 4 , 5 and 6 show the pattern pieces for the front and rear halves of right and left sleeves 48 , 50 , 52 and 54 respectively. These sleeve halves are substantially identical with the exception of a plurality of male snap fasteners 68 and female snap fasteners 66 on opposing separable top edges 56 and 64 and 84 and 86 . In a preferred embodiment sleeve halves 48 , 50 , 52 , and 54 have open end edges 58 , 62 , 78 an 82 that are approximately 11 inches long. Bottom edges 59 , 61 , 79 and 81 are approximately 8 inches long and are connected to neck sides 41 , 43 , 45 and 47 by curves edges 70 , 72 , 74 and 76 . Neck sides 41 , 43 , 45 and 47 are approximately 2 inches long. FIGS. 3 and 5 show four female snap fasteners 66 equally spaced along separable edges 56 and 86 . FIGS. 4 and 6 show four male snap fasteners 68 at matching locations on their separable edges 64 and 84 . The fasteners shown are for exemplary purposes and other releasable fastening devices such as ties or hook and eye systems may provide the separable connection means.
[0095] FIG. 7 shows right sleeve assembly 29 where bottom edges 59 and 61 are affixed in bottom seam 60 and left sleeve assembly 35 is shown in FIG. 7A where bottom edges 79 and 81 are affixed in bottom seam 80 .
[0096] FIG. 8 is a perspective front view of Multi-purpose Hospital Gown 10 that illustrates the assembled gown and the pockets and Foley catheter bag hanging slots and the side tie in frontal area 99 . FIG. 8 also shows the joining of right sleeve front 48 to body assembly 11 with body edge right sleeve front 32 sewn to edge 70 along seam 33 running from neck front 34 to right arm pit 95 . This view also shows the joining of left sleeve front 52 to body assembly 11 by affixing body edge left sleeve front 36 to edge 74 along seam 39 running from neck front 34 to left arm pit 97 . FIG. 9 shows the joining of right sleeve rear 50 to body assembly 11 by affixing body edge right sleeve rear 30 to edge 72 along seam 31 running from right top 96 to right arm pit 95 . This view also shows the joining of left sleeve rear 54 to body assembly 11 by affixing body edge left sleeve rear 38 to edge 76 along seam 39 running from left top 98 to left arm pit 97 . FIG. 9 is a perspective rear view of Multi-purpose Hospital gown 10 showing the rear ties at the neck and the wrap around feature.
[0097] Although this invention has been described by detailing a preferred embodiment with several optional attachments it is not intended to be limited to this set of materials and dimensions. Rather, the scope of this invention is defined by the following claims. | The present invention relates generally to hospital gowns and more specifically to gowns with specific pockets, slits to allow mounting catheter bag concealed inside gown of patient for maximum mobility and privacy with various monitors, catheters and lumens attached and passing through openings in gown to reach the patient's body and closures that are simple to use and provide for patient privacy with approximately 125% wrap around. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a divisional of U.S. application Ser. No. 13/807,582 (allowed) filed Feb. 7, 2013, which is a National Stage of International Application No. PCT/KR2011/004717, filed on Jun. 28, 2011, which claims the benefit of priority from Korean Patent Application No. KR 10-2010-0062374, filed on Jun. 29, 2010, the contents of which are herein incorporated by reference in their entirety.
TECHNICAL FIELD
[0002] The following disclosure relates to a film for food packaging and a method for manufacturing the same, and more particularly, to a film for food packaging capable of having excellent adhesion with a metal deposition layer and thus retaining excellent moisture barrier property while having superior flexibility, transparency, and biodegradability, and a method for manufacturing the same.
BACKGROUND
[0003] Polyethylene, polypropylene, polyvinyl chloride, polystyrene, polyester, and the like from petroleum are used for general plastic shrinkable films. Since these shrinkable films are chemically and biologically stable, they need a significantly long time to decompose, which causes serious environmental problems.
[0004] Currently, commonly used biodegradable shrinkable films are mainly made of polylactic acid, but since they have low shrinkage ratios and have brittle characteristics due to a crystallization phenomenon in a film manufacturing procedure, the uses thereof are limited. In order to improve the crystallization phenomenon, biodegradable aliphatic polyester having a glass transition temperature of 0° C. or lower is blended in the film manufacture procedure. However, the usability thereof is deteriorated to lead an increase in film opacity, resulting in limited uses thereof, and thermal characteristics of the resin blended itself leads to reduced productivity and the shrinkage ratios of final products are difficult to control, resulting in limited uses thereof.
[0005] In addition, since the other processes are not carried out in the manufacturing procedure of the final film, aluminum deposited after an aluminum deposition process for being used in food packaging and the like may be delaminated or separated, resulting in limited uses.
SUMMARY
[0006] An embodiment of the present invention is directed to providing a film for food packaging, capable of having excellent moisture barrier property as well as excellent transparency, flexibility, and biodegradability.
[0007] Specifically, an embodiment of the present invention is directed to providing a film for food packaging having excellent moisture barrier property, by forming a metal deposition layer on one surface of a biodegradable flexible/shrinkable film containing lactic acid as a main component. Here, an embodiment of the present invention is directed to providing a film for food packaging, capable of having no occurrence of delamination of a metal deposition layer due to printing and lamination after forming the metal deposition layer.
[0008] Specifically, an embodiment of the present invention is directed to providing a film for food packaging, capable of having improved adhesion with a metal deposition layer, by a biodegradable film containing a lactic acid of 10-99 wt % and an aliphatic or aliphatic-aromatic polyester resin of 1-90 wt %, of which biodegradability is 95% or more, shrinkage ratios in the machine direction and the transverse direction at the time of shrinkage in a water bath at 90° C. for 10 seconds are 5-60%, and tensile strength is 100-600 Kg/cm 2 , and a polyurethane coating layer formed on one surface of the biodegradable film.
[0009] Specifically, the present invention relates to a film for food packaging capable of having excellent moisture barrier property and a method for manufacturing the same. The film for food packaging of the present invention includes: a biodegradable film containing 10-99 wt % of lactic acid and 1-90 wt % of aliphatic or aliphatic-aromatic polyester resin; a polyurethane coating layer formed by coating a polyurethane coating composition on one surface of the biodegradable film; and a metal deposition layer formed on the polyurethane coating layer.
[0010] The film for food packaging of the present invention is characterized by the polyurethane coating layer in order to enhance adhesive strength between the biodegradable film and the metal deposition layer. In particular, the polyurethane coating layer is formed through an in-line coating method in the stretching process of the biodegradable film, so that there can be provided a film for food packaging, capable of having excellent adhesion with the biodegradable film, excellent adhesion with the metal deposition layer in a subsequent process, and low moisture permeability, and being superior in overall physical properties.
[0011] Further, a method for manufacturing a shrinkable film having excellent moisture barrier property of the present invention, the method includes:
[0012] a) preparing an unstretched film by melting and extruding 10-99 wt % of lactic acid and 1-90 wt % of aliphatic or aliphatic-aromatic polyester resin;
[0013] b) coating a water-dispersed polyurethane coating composition on one surface of the unstretched film through an in-line coating process;
[0014] c) uniaxially stretching the unstretched film coated with the water-dispersed polyurethane coating composition in the transverse direction (TD);
[0015] d) heat-treating the uniaxially stretched film at 50-100° C.; and
[0016] e) forming a metal deposition layer on a polyurethane coating layer of the uniaxially stretched film.
[0017] Hereinafter, the present invention will be described in more detail.
[0018] In the present invention, the biodegradable film is a uniaxially stretched film containing polylactic acid resin as a main component, and contains polylactic acid resin containing 10 wt % or more of lactic acid. More specifically, the biodegradable film contains 10-99 wt % of lactic acid. If the content of lactic acid is below 10 wt %, crystallinity is low and thus heat resistance may be significantly deteriorated, and uniform shrinkage by increased shrinkage stress may not occur. The content of the lactic acid is preferably 70 wt % or more, and more preferably 90 wt % or more. In addition, an anti-oxidant agent, a heat stabilizer, a UV blocking agent, and the like may be added without affecting expression characteristics of the biodegradable film of the present invention.
[0019] In addition to the raw material resin, aliphatic or aliphatic-aromatic polyester resin having a glass transition temperature of −60-60° C. may be blended for use together. As for the aliphatic polyester resin, at least one selected from the group consisting of phthalic acid dicarboxylic acid, diphenyl ether dicarboxylic acid, and the like, may be used at such a content that intrinsic biodegradability thereof is not affected. The biodegradable aliphatic/aromatic copolyester resin is prepared by polycondensation of aromatic dicarboxylic acid having a benzene ring, such as, dimethyl terephthalate or terephthalic acid, and aliphatic dicarboxylic acid, such as, succinic acid or adipic acid, as dicarboxylic acid components, and aliphatic (including cyclic aliphatic) glycol containing at least one selected from 1,4-buthandiol and ethylene glycol. Here, the mole ratio of aliphatic dicarboxylic acid and aromatic dicarboxylic acid is 60:40 to 50:50.
[0020] In the present invention, examples of the biodegradable aliphatic polyester resin may include polylactone, polybutylene succinate, and the like, but are not limited thereto.
[0021] The content of the aliphatic or aliphatic-aromatic polyester resin is preferably 1-90 wt % based on the total weight of raw materials. If the content thereof is above 90 wt %, kneadability with polylactic acid may be deteriorated and thus film formation is difficult, thermal characteristics may be deteriorated, and opacity of the final film may be increased. If the content thereof is below 1 wt %, it may be difficult to impart flexibility to a film. The content of the aliphatic or aliphatic-aromatic polyester resin is preferably 5-80 wt % and more preferably 30-60 wt % in view of transparency and flexibility of the film.
[0022] As the biodegradable film of the present invention, a biodegradable film having opacity of 30% or lower, biodegradability of 95% or higher, shrinkage ratios in the machine direction (MD) and the transverse direction (TD) at the time of shrinkage in a water bath at 90° C. for 10 seconds of 5-60%, and tensile strength of 100-600 Kg/cm 2 is preferably used.
[0023] If opacity thereof is above 30%, the film may not be used for a packaging purpose for showing the inside, and thus the use of the film is limited. In addition, as for the biodegradable film, the shrinkage ratios in the machine direction (MD) and the transverse direction (TD) at the time of shrinkage in a water bath at 90° C. for 10 seconds are preferably 5-60%. If the shrinkage ratio is below 5%, shrinkage is too small and thus the film may not be applied to various types of containers, and problems on external appearance may occur even though the film shrinks. If the shrinkage ratio is above 60%, the shrinking rate is fast and thus problems on external appearance may occur. The tensile strength is preferably 100-600 kg/cm 2 . If the tensile strength is below 100 Kg/cm 2 , wrinkles may be generated due to mechanical tension, resulting in defective printing, in the subsequent processes such as printing and laminating, or fracture may occur in the subsequent processes. If the tensile strength is above 600 Kg/cm 2 , the film may be brittle and thus may be easily fractured or broken due to external impact. The tensile strength is preferably 200 Kg/cm 2 -550 Kg/cm 2 , and more preferably 300 Kg/cm 2 -500 Kg/cm 2 .
[0024] Then, in the present invention, the polyurethane coating layer is configured to enhance adhesive strength between the biodegradable film and the metal deposition layer, and is preferably formed by coating a water-dispersed polyurethane coating composition through an in-line coating process. Here, the coating thickness, which is a dried coating thickness, is preferably 0.01-0.1 μm since excellent adhesion is obtained without affecting physical properties such as moisture barrier property of the film. More specifically, the water-dispersed polyurethane coating composition contains 0.5-1.0 wt % of polyurethane based binder resin, 0.01-0.5 wt % of a silicon based wetting agent, and the remainder water.
[0025] In the present invention, the metal deposition layer made of such as aluminum layer or the like is formed on one surface of the film, more specifically, on the polyurethane coating layer, in order to more improve moisture barrier property of the final film. Sputtering or the like may be employed for a depositing method, and the deposition thickness of the metal deposition layer is preferably 200 Å or more, more preferably 200-1000 Å, and most preferably, 500 Å-1000 Å. If the thickness of the metal deposition layer is below 200 Å, moisture barrier property required may not be satisfied, and thus the use of the film may be limited.
[0026] In the film for food packaging of the present invention, peeling strength of the metal deposition layer needs to be 100 g/cm or higher at room temperature and hydrothermal treatment (95° C., 30 min) after deposition of aluminum or the like. If the peeling strength is below 100 g/cm, the metal deposition layer may be delaminated during procedures of transfer, storage, and the like of products. The peeling strength is preferably 120 g/cm and more preferably 150 g/cm. In addition, the film having moisture permeability of 1×10 −2 -1×10 −4 (g/m 2 ×day) is suitably used as a film for food packaging.
[0027] Hereinafter, a method for manufacturing the film for food packaging of the present invention will be described in detail. The procedure of manufacturing a film for food packaging of the present invention may be divided into preparing an unstretched film by melting and extruding biodegradable resin; uniaxially stretching the unstretched film; performing heat-setting; performing cooling; and forming a metal deposition layer on the uniaxially stretched film.
[0028] More e specifically, the method for manufacturing a film for food packaging, the method including:
[0029] a) preparing an unstretched film by melting and extruding 10-99 wt % of lactic acid and 1-90 wt % of aliphatic or aliphatic-aromatic polyester resin;
[0030] b) coating a water-dispersed polyurethane coating composition on one surface of the unstretched film through an in-line coating process;
[0031] c) uniaxially stretching the unstretched film coated with the water-dispersed polyurethane coating composition in the transverse direction (TD);
[0032] d) heat-treating the uniaxially stretched film at 50-100° C.; and
[0033] e) forming a metal deposition layer with a thickness of 200 Å-1000 Å on a polyurethane coating layer of the uniaxially stretched film.
[0034] Herein, in the melting and extruding of the step a), the raw material resin is melted, kneaded, and extruded by using an extruder at 180-220° C., and then is rapidly cooled and solidified passing through cooling rollers, to thereby obtain an unstretched film. Here, the temperature of the cooling rollers is preferably 10-60° C. If the temperature of the cooling rollers is below 10° C., the crystallizing rate may be too fast, resulting in increasing opacity, and the raw material resin may not adhere to the cooling rollers, resulting in surface defects due to non-uniform cooling. If the temperature of the cooling rollers is above 60° C., the raw material resin may adhere to the cooling rollers and thus manufacturing of the film is difficult. The temperature of the cooling rollers is preferably 20-50° C. and more preferably 25-40° C.
[0035] Next, the unstretched film is passed through rollers transferred in a machine direction (MD), subjected to an in-line coating (ILC) process, passed through a preheating section of 70-90° C., stretched at a stretching ratio of 3-6 times in a transverse direction (TD) at 60-80° C., and then passed through a heat treatment section of 50-100° C., to thereby manufacture a film. If the temperature for heat treatment is below 50° C., the shrinkage ratio may be excessively increased. If the temperature of heat treatment is above 100° C., the shrinkage ratio required may not be obtained, and thus the use of the film is limited.
[0036] In the uniaxial stretching of the unstretched film, the in-line coating (ILC) process employs a water-dispersed polyurethane coating composition, and the water-dispersed polyurethane coating composition contains a polyurethane resin solid content of 0.5 to 1.0 wt %, a silicon based wetting agent of 0.01-0.5 wt %, and the remainder water.
DETAILED DESCRIPTION OF EMBODIMENTS
[0037] Hereinafter, the present invention will be in detail described by examples, but the present invention is not limited to the following examples.
[0038] Hereinafter, polylactic acid resin used in examples and comparative examples was 4032D purchased from NatureWorks LLC, having a melting point of 170° C., a glass transition temperature of 62° C., and a lactic acid content of 98.5%.
Example 1
[0039] A master batch was prepared by adding 60% of polylactic acid resin as raw material resin, polylactone (DAICELL Chemical Company, Celgreen), and silicon dioxide having an average particle size of 2.7 μm so as to be 450 ppm in a final film, followed by blending. The master batch was dried at 110° C. for 2 hours by using a hot air drier, melted and extruded at 200° C., and rapidly cooled and solidified passing through cooling rollers of 25° C., to thereby prepare an unstretched film.
[0040] A water-dispersed polyurethane coating composition was coated on one surface of the unstretched film through an in-line coating (ILC) process such that the dried coating thickness thereof was 0.04 μm. The water-dispersed polyurethane coating composition contained 0.8 wt % of solid of polyurethane resin (DKC, Superflex 210), 0.1 wt % of silicon based wetting agent (DowCorning, Q2-5212), and the remainder water.
[0041] The unstretched film coated with the water-dispersed polyurethane coating composition was passed through a preheating section of 80° C. using rollers transferred in a machine direction (MD), stretched at a stretching ratio of 4.0 times in a transverse direction (TD) at 70° C., and then passed through a heat treatment section of 90° C., to thereby manufacture a film. Physical properties of the manufactured film were shown in Table 1.
[0042] An aluminum deposition layer with a thickness of 1000 Å was formed on one surface of the manufactured film by using a metal deposition system, to thereby manufacture a final film. Physical properties of the manufactured deposition film were shown in Table 1.
Example 2
[0043] A film was manufactured by the same method as Example 1, except that a master batch was prepared by using 45 wt % of polylactone, and physical properties of the film were shown in Table 1.
Example 3
[0044] A film was manufactured by the same method as Example 1, except that a master batch was prepared by using 30 wt % of polylactone, and physical properties of the film were shown in Table 1.
Example 4
[0045] A film was manufactured by the same method as Example 1, except that a master batch was prepared by using polybutylene succinate resin instead of polylactone, and physical properties of the film were shown in Table 1.
Example 5
[0046] A film was manufactured by the same method as Example 1, except that the thickness of the metal deposition layer was 200 Å, and physical properties of the film were shown in Table 1.
Comparative Example 1
[0047] A film was manufactured by the same method as Example 1, except that an in-line coating process is omitted and the temperature for a heat treatment section was 30° C., and physical properties of the film were shown in Table 1.
Comparative Example 2
[0048] A film was manufactured by the same method as Example 1, except that an in-line coating process is omitted and the temperature for a heat treatment section was 150° C., and physical properties of the film were shown in Table 1.
[0049] Characteristics of the films manufactured in Examples 1 to 5 and Comparative Examples 1 and 2 were evaluated.
[0050] 1. Lactic Acid Content
[0051] Lactic acid content was measured using an automatic polarimeter (P-1020) at a wavelength of 589 nm of a sodium lamp and calculated by using software.
[0052] 2. Tensile Strength
[0053] Tensile strength in a transverse direction of a film was measured by using a tensile test machine according to ASTM D 882.
[0054] 3. Shrinkage Ratio
[0055] A film was cut into a rectangular size of 15mm (MD)×400 mm (TD) in a machine direction (MD) and a transverse direction (TD). An unbroken line was drawn at 50 mm from both ends of the rectangular film in the TD along the MD, to thereby prepare a sample having an effective measurement length of 300 mm. The sample was completely immersed in warm water of 90° C.±0.5° C. under non-load while tweezers hold within 50 mm from one end of the sample without distinction of left and right, and in that state, the film was thermally shrunken for 10 seconds, and then left at room temperature for 1 minute. A reduced length of the measurement length of 300mm in the TD, which was initially indicated by the unbroken line, was measured, to thereby obtain a thermal shrinkage ratio in the TD of the film according to Equation 1 below.
[0000] Thermal shrinkage ratio (%)=(300 mm-length after shrinkage)/300 mm×100 [Equation 1]
[0056] 4. Opacity
[0057] Opacity was measured according to ASTM D-1003. Two edge sites, one center site, and seven random sites on a biodegradable flexible/shrinkage film were extracted, and then were cut into 5 cm×5 cm sizes. Opacity thereof (Haze, %) was measured by placing each in a film haze meter (NDH-5000). Five measurement values except for the maximum value and the minimum value were averaged, so that opacity (Haze, %) was calculated.
[0058] 5. Biodegradability
[0059] The ratio of biodegradability value thereof measured according to KS M3100-1(2003) based on that of a standard material was calculated by Equation 2 below.
[0000] Ratio of Biodegradability (%)=(biodegradability of sample/biodegradability of standard material)×100 [Equation 2]
[0060] 6. Peeling Strength
[0061] 50 wt % of thermosetting polyurethane based adhesive (Neoforce, KUB-3385) and 50 wt % of ethylacetate as a solvent were used with respect to an aluminum deposition layer of a deposition film, and 11 wt % of a polyurethane based curing agent (Neoforce, CL-100) was used with respect to 100wt % of the adhesive. At the time of laminating, first laminating was performed by allowing 5 kg-rolls to reciprocate in the laminating section, and second laminating was performed on the first laminated sample by using a laminator with non-heat at speed level 3. This sample was hardened in a hot air oven of 60° C. for 15 hours under a pressure of 16 g/cm 2 . The thus laminated sample was cut at a width interval of 1 cm, and then peel strength (g/cm) between an aluminum deposition layer and a polyurethane coating layer was measured in a 180° peel manner by using a friction factor measuring instrument.
[0062] 7. Moisture Permeability
[0063] Moisture Permeability was measured according to ASTM D-3985. The final deposition film was cut into A4-size, which was then placed in a moisture meter (Permatran-W, Model 3/61). Then, moisture permeability (g/m 2 ×day) was measured seven times at 38° C.±2° C. and 100 RH %, and five measurement values except for the maximum value and the minimum value were averaged, to thereby calculate moisture permeability (g/m 2 ×day).
[0000]
TABLE 1
Uniaxially Stretched Film
Deposition Film
Tensile
Shrinkage
Peel
Moisture
Strength
ratio
Opacity
Biodegradability
Strength
Permeability
Kg/cm 2
%
%
%
g/cm
g/m 2 × day
Example 1
390
37
4.0
100
105
2.7 × 10 −3
Example 2
412
36
3.1
100
108
4.3 × 10 −3
Example 3
513
36
2.2
100
103
7.2 × 10 −3
Example 4
385
38
3.9
100
104
3.3 × 10 −3
Example 5
386
36
4.0
100
97
3.2 × 10 −1
Comparative
388
76
4.2
100
58
8.7 × 10 −2
Example 1
Comparative
393
7
4.1
100
61
5.7 × 10 −2
Example 2
[0064] It was confirmed from the results of Table 1 above that the biodegradable flexible/shrinkable film according to the present invention had excellent shrinkage, transparency, flexibility, deposition, and the like. Whereas, it can be seen that, in Comparative Example 1 out of the ranges of the present invention, the temperature for heat treatment of the biodegradable film was too low, resulting in lowering shrinkage ratio, and the polyurethane coating layer was not formed between the biodegradable film and the metal deposition layer, resulting in significantly decreasing peel strength of the metal deposition layer. In addition, it can be seen that, in Comparative Example 2, the temperature for the heat treatment section was too high, and thus the shrinkage ratio was too low.
[0065] The film for food packaging according to the present invention has excellent uniformity in shrinkage, transparency, flexibility, and deposition, and thus, can not be easily fractured by defects due to delamination of the deposition layer and external impact at the time of transfer/storage and can be used as various kinds of packaging materials in virtue of intrinsic flexibility thereof.
[0066] As set forth above, the film for food packaging according to the present invention has uniform shrinkage, transparency, flexibility, and deposition, and thus can not be easily broken by defects due to delamination of the deposition layer and external impact at the time of transfer/storage thereof, and can be used as various kinds of packaging materials due to intrinsic flexibility thereof. | Provided are a film for food packaging, capable of having excellent adhesion with a metal deposition layer and thus retaining moisture barrier property while having superior flexibility, transparency, and biodegradability, and a method for manufacturing the same. | 8 |
RELATED APPLICATIONS
This application is a continuation-in-part application of my copending application Ser. No. 07/322,526 filed March 13, 1989, now abandoned for DISPOSABLE BAG APPARATUS AND METHOD.
BACKGROUND
1. Field of the Invention
This invention relates to disposable bags and, more particularly, to a disposable bag apparatus and method wherein the open mouth at the upper end of a convergently tapered plastic bag is inverted into the plastic bag to form a reflux valve on the end of a funnel inserted into the plastic bag.
2. The Prior Art
Numerous varieties of disposable bags are used for the collection and subsequent disposal of various waste materials. These bags range from the simple plastic bag adapted to being tied off with a string, bag tie, or the like, to highly complex bag and valve systems such as that disclosed in the patent of Fleury, et al. (U.S. Pat. No. 3,797,734). The Fleury patent is directed to a funnel/bag combination wherein the funnel includes a reflux valve mounted to the lower end of the funnel. The bag is a conventional plastic bag of tubular construction with the funnel mounted in the mouth of the bag. The funnel is configured with two parallel panels that can be opened upon being squeezed from opposite edges. The valve consists of two separate sheets of plastic material suspended from each side of the funnel mouth. Liquid passing through the funnel falls into the bag between the two sheets of the valve. The sheets, being wetted by the falling liquid, tend to cling together creating a one way valve mechanism for the funnel.
Regrettably, the disposable bag of the foregoing patent is fairly complex in that it requires a number of extra parts and corresponding assembly steps thereby rendering the bag inherently more expensive for most disposable bag applications. What is needed is a simple, safe, disposable bag apparatus that is relatively inexpensive to fabricate so that it can be widely used throughout the healthcare and transportation industries. Such a novel, disposable bag apparatus and method is disclosed and claimed herein.
BRIEF SUMMARY AND OBJECTS OF THE INVENTION
This invention includes a unique combination of a flattened funnel sealingly mounted in the throat of a tapered, plastic bag. The mouth and a portion of the neck of the tapered, plastic bag are inverted into the bag where it creates a funnel extension on the lower end of the folded funnel as well as a reflux valve against accidental reflux of contents from the bag. One side of the funnel extends above the open end of the funnel to form a closure that can be folded over the flattened funnel to sealingly close both the funnel and the bag.
In view of the foregoing, it is a primary object of this invention to provide improvements in disposable bags.
Another object of this invention is to provide improvement in the method of collecting waste in a disposable bag for subsequent disposal.
Another object of this invention is to provide a novel, tapered, plastic bag wherein the mouth and a portion of the neck of the tapered, plastic bag is inverted inwardly into the bag to create a reflux valve mechanism when a funnel is sealingly engaged in the throat of the resulting plastic bag.
Another object of this invention is to provide a closure to the funnel inserted into the throat of the plastic bag.
Another object of this invention is to provide a funnel with a tapered portion that matches a portion of the taper in the throat of the tapered, plastic bag.
These and other objects and features of the present invention will become more readily apparent from the following description in which preferred and other embodiments of the invention have been set forth in conjunction with the accompanying drawing and appended claims.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a front view of the novel, disposable bag of this invention;
FIG. 2 is the front view of the novel, disposable bag shown in FIG. 1 with portions broken away to reveal internal features;
FIG. 3 is a front view of the tapered, plastic bag with a portion of the neck and mouth of the plastic bag shown schematically as being inverted inside the plastic bag (as shown by broken lines);
FIG. 4 is a front view of the tapered funnel that is sealingly mounted inside the throat of the plastic bag; and
FIG. 5 is a side view of the closed, disposable bag of this invention with portions broken away to reveal internal features.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The invention is best understood by reference to the drawing wherein like parts are designated by like numerals throughout in conjunction with the following description.
GENERAL DISCUSSION
The collection and subsequent disposable of human vomitus is a serious problem not only in healthcare facilities such as hospitals and nursing homes but also in all forms of transportation such as personal vehicles, trains, aircraft, ships, and the like. Historically, healthcare facilities rely on an inexpensive emesis basin that is designed as a single patient, reusable basin that is intended to be discarded when the patient is discharged. This device, though inexpensive, is designed to be flushed and cleansed after each use. Both users and nursing personnel universally dislike this conventional emesis basin because it is not only too small but also exposes to view and smell the vomitus deposited therein. Further, since these devices must be flushed and cleansed after each use there is considerable risk of secondary contamination by the contents through splashing, spillage, and the like.
The recent concern over the spread of infectious organisms via vomitus, particularly the virus responsible for the deadly disease known as AIDS (Acquired Immune Deficiency Syndrome) has resulted in extreme caution being taken in dealing with any kinds of body fluids, such as vomitus. Accordingly, there is an emerging trend to use disposable plastic bags for the collection and subsequent disposal of such products. Plastic bags are widely used for the collection of vomitus and are found readily available in aircraft, for example, for the convenience of passengers. However, a simple plastic bag must be held open with both hands rendering the user helpless in conditions of rough weather, dizziness, or the like. The foregoing disposable bag of Fleury, et al. (U.S. Pat. No. 3,797,734) clearly solves most of these problems in that it provides a funnel that permits the user to hold the bag and funnel open with only one hand.
DETAILED DESCRIPTION
Referring now more particularly to FIGS. 1 and 2, the novel, disposable bag of this invention is shown generally at 10 and includes a plastic bag 12 having a tapered neck 20 (see also FIG. 3) with a partially flattened funnel 14 inserted in its throat at fold 22. Plastic bag 12 is tapered convergently in the upward direction (FIG. 3) with a slight taper 13 so that neck 20 can be inverted internally into plastic bag 12 at fold 22 to form a throat 20a (shown by broken lines) with mouth 24 becoming outlet 24a. Plastic bag 12 is elongated sufficiently to accommodate the necessary length to neck 20 so that it can be folded inwardly or otherwise inverted at fold 22.
Referring now also to FIG. 4, funnel 14 is shown partially opened from its conventional flattened condition (see FIG. 5) for storage (now shown). Funnel 14 includes flattened side elements 30 between inlet 34 and an outlet 36 and has tapered sides 15 corresponding to a lower section 31 and slightly differently tapered sides 17 corresponding to an upper section 32. The change in taper between tapered sides 15 and tapered sides 17 occurs at crease 22a (shown by broken lines). The dimensions of funnel 14 at crease 22a are configured to conform with the dimensions of plastic bag 12 at fold 22. Further, the angular taper of tapered side 15 corresponds to angular taper of taper 13 of plastic bag 12 so that lower section 3 (of funnel 14 can be sealingly engaged in the throat of neck 20 (as shown in FIGS. 1, 2 and 5). The slightly outward flaring of tapered side 17 provides a convenient catchment for more securely holding funnel 14 in the hand (not shown) of user. Crease 22a also assists in the assembly of disposable bag 10 by providing a stop against which fold 22 is brought into contact during assembly.
A closure 38 is formed as an extension of one of the sidewalls of funnel 14 and is adapted to be folded at fold 32 across the open mouth 34 of funnel 14 into contact with the other side of side elements 30. An adhesive strip under overlay 37 seals closure 38 across funnel 14. Edges 39 of closure 38 are tapered inwardly in a taper that corresponds angularly with the taper of tapered sides 17.
Historically, most plastic bags are configured with a tubular construction meaning that the sidewalls are parallel along the length of the bag. Plastic bag 12 is unique in that it has a convergent taper 13 oriented upwardly toward mouth 24. When mouth 24 and the adjoining neck 2 is inverted into plastic bag 12 neck 20 becomes a funnel extension 20a (FIG. 3) that diverges away from the adjacent sidewalls to create a reflux valve mechanism. Advantageously, the reflux valve acts against the accidental reflux of contents from the interior of plastic bag 12.
With particular reference to FIG. 5, plastic bag 12 with vomitus 40 therein has been closed by funnel 14 being flattened into the flat configuration. Flap 38 has been folded downwardly over open mouth 34 along fold 32 to close the same. Overlay 37 (FIGS. 1, 2, and 4) covers a corresponding adhesive strip (not shown) on closure 38 so that the adhesive can sealingly engage the underlying portion of funnel 14. With closure 38 sealingly engaged across the open mouth 34 of funnel 14 the entire length of funnel 14 cooperates with the downwardly depending neck 20 of plastic bag 12 to provide an elongated, closed valve mechanism against the accidental reflux of vomitus 40 from plastic bag 12. The Method
In practicing the method of this invention, a plastic bag 12 having tapered sidewalls 13 is fabricated into a vomitus receiving bag by inverting neck 20 inwardly into plastic bag 12 at fold 22 so that neck 20 becomes a funnel extension 20a and mouth 24 becomes an outlet 24a (FIG. 3). Funnel extension 20a thereby becomes a unidirectional valve to prevent the reflux of vomitus 40 since any reverse movement of vomitus 40 will collapse funnel extension 20a thereby preventing such reflux. A funnel for plastic bag 12 is fabricated from a suitable material such as a relatively stiff plastic or paper material such as the paper stock used for the fabrication of milk cartons, and the like. Funnel 14 is configured with a flattened configuration having tapered sidewalls 15 that match the taper of sidewalls 13. Funnel 14 is inserted into the open throat of neck 20 at fold 22. Funnel 14 will fit partway into the resulting opening with the fold 22 corresponding with the fold line 22a (FIG. 4). Adhesive is applied to section 31 on the lower end of funnel 14 so as to provide a relatively wide sealed surface between funnel 14 and plastic bag 12. A second strip of adhesive is applied to the upper end of flap 38 and covered with a removable cover 37.
With disposable bag 10 thus assembled, the downwardly depending plastic bag 12 can be folded and the entire assembly of disposable bag 10 inserted into a convenient envelope (not shown) or the like. Importantly, flap 38 is presented in an exposed manner so that it can be readily grasped and funnel 14 pulled upwardly by the user (not shown) for the rapid deployment of plastic bag 12. In particular, the user grasps funnel 14 along tapered sides 15 and, upon squeezing inwardly, outwardly deforms the two sidewalls of funnel 14 thus creating an opening having a generally oval cross section. During use, flap 38 provides a limited amount of privacy to the user (not shown) and may be quickly folded over and adhesively secured to the upper end 32 of funnel 14 thereby substantially eliminating odors and accidental reflux of vomitus 40.
The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope. | This invention is a disposable bag having a foldable funnel mounted in the throat of the bag. The bag has a convergent, upwardly tapered neck toward the mouth of the bag. The mouth and a portion of the neck are inverted inside the bag where it forms a reflux valve below the funnel. One side of the funnel includes an upwardly extending closure that can be folded across the funnel into sealing engagement with the other side of the funnel. | 8 |
FIELD AND BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates generally to the field of emission control equipment for boilers, heaters, kilns, or other flue gas-, or combustion gas-, generating devices (e.g., those located at power plants, processing plants, etc.) and, in particular to a new and useful method and apparatus for preventing the plugging, blockage and/or contamination of an SCR catalyst. In another embodiment, the method and apparatus of the present invention is designed to protect an SCR catalyst from plugging and/or blockage from large particle ash that may be generated during combustion.
[0003] 2. Description of the Related Art
[0004] NO x refers to the cumulative emissions of nitric oxide (NO), nitrogen dioxide (NO 2 ) and trace quantities of other nitrogen oxide species generated during combustion. Combustion of any fossil fuel generates some level of NO x due to high temperatures and the availability of oxygen and nitrogen from both the air and fuel. NO x emissions may be controlled using low NO x combustion technology and post-combustion techniques. One such post-combustion technique is selective catalytic reduction using an apparatus generally referred to as a selective catalytic reactor or simply as an SCR.
[0005] SCR technology is used worldwide to control NO x emissions from combustion sources. This technology has been used widely in Japan for NO x control from utility boilers since the late 1970's, in Germany since the late 1980's, and in the US since the 1990's. The function of the SCR system is to react NO x with ammonia (NH 3 ) and oxygen to form molecular nitrogen and water. Industrial scale SCRs have been designed to operate principally in the temperature range of 500° F. to 900° F., but most often in the range of 550° F. to 750° F. SCRs are typically designed to meet a specified NO x reduction efficiency at a maximum allowable ammonia slip. Ammonia slip is the concentration, expressed in parts per million by volume, of unreacted ammonia exiting the SCR.
[0006] For additional details concerning NO x removal technologies used in the industrial and power generation industries, the reader is referred to Steam: its generation and use, 41 st Edition, Kitto and Stultz, Eds., Copyright© 2005, The Babcock & Wilcox Company, Barberton, Ohio, U.S.A., particularly Chapter 34—Nitrogen Oxides Control, the text of which is hereby incorporated by reference as though fully set forth herein.
[0007] Regulations (March 2005) issued by the EPA promise to increase the portion of utility boilers equipped with SCRs. SCRs are generally designed for a maximum efficiency of about 90%. This limit is not set by any theoretical limits on the capability of SCRs to achieve higher levels of NO x destruction. Rather, it is a practical limit set to prevent excessive levels of ammonia slip. This problem is explained as follows.
[0008] In an SCR, ammonia reacts with NO x according to the following stoichiometric reactions (a) to (c):
[0000] 4NO+4NH 3 +O 2 →4N 2 +6H 2 O (a)
[0000] 12NO 2 +12NH 3 →12N 2 +18H 2 O+3O 2 (b)
[0000] 2NO 2 +4NH 3 +O 2 →3N 2 +6H 2 O (c).
[0009] The above reactions are catalyzed using a suitable catalyst. Suitable catalysts are discussed in, for example, U.S. Pat. Nos. 5,540,897; 5,567,394; and 5,585,081 to Chu et al., all of which are hereby incorporated by reference as though fully set forth herein. Catalyst formulations generally fall into one of three categories: base metal, zeolite and precious metal.
[0010] Base metal catalysts use titanium oxide with small amounts of vanadium, molybdenum, tungsten or a combination of several other active chemical agents. The base metal catalysts are selective and operate in the specified temperature range. The major drawback of the base metal catalyst is its potential to oxidize SO 2 to SO 3 ; the degree of oxidation varies based on catalyst chemical formulation. The quantities of SO 3 which are formed can react with the ammonia carryover to form various ammonium-sulfate salts.
[0011] Zeolite catalysts are aluminosilicate materials which function similarly to base metal catalysts. One potential advantage of zeolite catalysts is their higher operating temperature of about 970° F. (521° C.). These catalysts can also oxidize SO 2 to SO 3 and must be carefully matched to the flue gas conditions.
[0012] Precious metal catalysts are generally manufactured from platinum and rhodium. Precious metal catalysts also require careful consideration of flue gas constituents and operating temperatures. While effective in reducing NO R , these catalysts can also act as oxidizing catalysts, converting CO to CO 2 under proper temperature conditions. However, SO 2 oxidation to SO 3 and high material costs often make precious metal catalysts less attractive.
[0013] As is known to those of skill in the art, various SCR catalysts undergo plugging and/or poisoning when they become contaminated by various compounds including, but not limited to, ash from the combustion process (in particular coal ash). One common source of plugging in SCRs is large particle ash (typically defined as any ash that has a particle size large enough to lodge in the catalyst passages, pores, or honeycomb structure present in the SCR catalyst blocks).
[0014] Given the above, a need exists for a system and method that can prevent the plugging and/or poisoning of a catalyst in an SCR with fly ash, particularly large particle ash.
SUMMARY OF THE INVENTION
[0015] The present invention relates generally to the field of emission control equipment for boilers, heaters, kilns, or other flue gas-, or combustion gas-, generating devices (e.g., those located at power plants, processing plants, etc.) and, in particular to a new and useful method and apparatus for preventing the plugging, blockage and/or contamination of an SCR catalyst. In another embodiment, the method and apparatus of the present invention is designed to protect an SCR catalyst from plugging and/or blockage from large particle ash that may be generated during combustion.
[0016] Accordingly, one aspect of the present invention is drawn to a system for increasing the active life of an SCR catalyst, the system comprising: (i) at least one first flue gas conduit designed to transport flue gas from a combustion zone to an SCR; (ii) at least one SCR positioned between the at least one first flue gas conduit and at least one second flue gas conduit, wherein the at least one second flue gas conduit is designed to transport flue gas from the SCR to additional downstream systems or environmental controls; (iii) at least one large particle ash screen positioned in the at least one first flue conduit so as to enable the collection of at least about 50 percent of any large particle ash present in the flue gas prior to the entry of the flue gas into the at least one SCR; and (iv) at least one rotary valve positioned to be in working communication with the large particle ash screen, wherein the at least one rotary valve is designed to collect any large particle ash captured by the at least one large particle ash screen and supply such large particle ash to the at least one second flue gas conduit.
[0017] Another aspect of the present invention is drawn to a system for increasing the active life of an SCR catalyst, the system comprising: (A) at least one first flue gas conduit designed to transport flue gas from a combustion zone to an SCR, the at least one first flue gas conduit being designed to permit the flue gas to flow at a first flow velocity; (B) at least one second flue gas conduit that is in operative communication with the at least one first flue gas conduit, wherein the at least one second flue gas conduit is designed to transport flue gas from the at least one first flue gas conduit to an SCR, the at least one second flue gas conduit being designed to permit the flue gas to flow at a second flow velocity, and the second flow velocity is at least 10 percent less than the first flow velocity; (C) at least one third flue gas conduit designed to transport flue gas from the SCR to additional downstream systems or environmental controls; and (D) at least one rotary valve positioned to be in working communication with the at least one second flue gas conduit, wherein the at least one rotary valve is designed to collect any large particle ash captured in the at least one second flue gas conduit and supply such large particle ash to the at least one third flue gas conduit, wherein the combination of the at least one second flue gas conduit and the at least one rotary valve enable the collection of at least about 50 percent of any large particle ash present in the flue gas prior to the entry of the flue gas into the at least one SCR.
[0018] In yet another aspect of the present invention, there is provided a method for increasing the active life of an SCR catalyst, the method comprising the steps of: (a) providing at least one large particle ash collection means designed to collect large particle ash in a flue gas stream upstream of the entry of the flue gas into an SCR; and (b) collecting the large particle ash in the at least one large particle ash collection means so as to remove at least about 50 percent of the large particle ash from the flue gas stream prior to entry of the flue gas stream into the SCR; and (c) supplying the collected large particle ash to a point in the flue gas stream downstream of the SCR.
[0019] 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 benefits attained by its uses, reference is made to the accompanying drawings and descriptive matter in which exemplary embodiments of the invention are illustrated.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIG. 1 is a schematic representation of a typical prior art fossil fuel burning facility, designed and initially provided with an SCR system;
[0021] FIG. 2 is a schematic representation of another typical prior art fossil fuel burning facility which was not designed or initially provided with an SCR system;
[0022] FIG. 3 is a schematic representation of the fossil fuel burning facility of FIG. 2 , to which an SCR system and the present invention have been added;
[0023] FIG. 4 is a close-up, perspective view illustrating the arrangement of the flues from the boiler and the lower outlet portion of the SCR of FIG. 3 , in accordance with one embodiment of the present invention;
[0024] FIG. 5 is a side view of the arrangement of the flues from the boiler and the lower outlet portion of the SCR of FIG. 4 , in accordance with one embodiment of the present invention; and
[0025] FIG. 6 is a cross-sectional view of the arrangement of the flues from the boiler and the lower outlet portion of the SCR of FIG. 4 , viewed in the direction of arrows 6 - 6 of FIG. 3 .
DESCRIPTION OF THE INVENTION
[0026] While the present invention will be described in terms of SCR systems which use ammonia as the NO reducing agent, since ammonia is frequently preferred for economic reasons, the present invention is not limited to ammonia based systems. The concepts of the present invention can be used in any system which uses an ammoniacal compound. As used in the present disclosure, an ammoniacal compound is a term meant to include compounds such as urea, ammonium sulfate, cyanuric acid, and organic amines as well as ammonia (NH 3 ). These compounds could be used as reducing agents in addition to ammonia, but as mentioned above, ammonia is frequently preferred for economic reasons. Some non-ammoniacal compounds such as carbon monoxide or methane can be used as well, but with loss in effectiveness.
[0027] Although the present invention is described in relation to a boiler, or a fossil fuel boiler, it is not limited solely thereto. Instead, the present invention can be applied to any combustion source that generates NO regardless of whether such a combustion source is utilized in conjunction with a boiler, or a steam generator. For example, the present invention could be used in combination with a kiln, a heater, or any other type of combustion process that generates, in whole or in part, a flue gas or combustion gas containing NO x . Accordingly, the description below is to be construed as merely exemplary. Additionally, the present invention can be applied to any SCR regardless of the type of catalyst that is utilized therein. As such, the present invention is not limited to any one type of SCR catalyst, but rather is broadly applicable to a wide range of SCR catalyst systems. Suitable catalyst systems for which the present invention is applicable include, but are not limited to, honeycomb, corrugated and plate-type catalysts.
[0028] In one embodiment, the present invention is directed to reducing the rate of SCR catalyst deactivation on Powder River Basin (PRB) coal combustion units. It should be noted that although the present invention is described in relation to PRB coal, the present invention is not limited thereto. Rather, the present invention is broadly applicable to any situation where an SCR catalyst is plugged, blocked and/or contaminated by large particle ash (LPA) that accumulates in the catalyst passages, pores, or honeycomb structure present in the SCR catalyst blocks.
[0029] In one embodiment, PRB coal is suspected to cause plugging, blockage and/or contamination of the catalyst passages, pores, or honeycomb structure present in the SCR catalyst blocks due to the presence of LPA which can be characterized, in a non-limiting manner, as popcorn ash. While not wishing to be bound to any one definition, LPA is defined as ash having a mean particle size of at least about 4 mm, or even at least about 6 mm. In one embodiment, LPA has any type of geometry including, but not limited to, irregular geometries, spherical geometries, oblong geometries, ellipsoidal geometries, or any combination of two or more thereof. In another embodiment, LPA is defined as any ash that is larger than the catalyst passages, pores, or honeycomb structure present in the SCR catalyst blocks. In this embodiment, the size of the LPA only has to be sufficient to cause plugging, blockage and/or contamination of the catalyst in the SCR.
[0030] In one embodiment, the present invention relates to a system and method to prevent plugging, blockage and/or contamination of the catalyst passages, pores, or honeycomb structure present in the SCR catalyst blocks due to the presence of LPA. In one embodiment, the present invention accomplishes the aforementioned goal by the addition of at least one LPA screen and at least one rotary valve located at a position in the flue conduit downstream of the boiler but upstream of the SCR designed to remove at least about 50 percent of the LPA present in the flue gas stream. In another embodiment, the present invention is designed to remove at least about 75 percent, at least about 85 percent, at least about 95 percent, or even at least about 99 percent of
[0031] Turning to the Figures, FIG. 1 is an illustration of a typical power plant that utilizes coal as a combustion source, and which was designed and initially provided with an SCR system. As can be seen in FIG. 1 , a typical power plant includes a SCR located between a boiler portion of the power plant and a spray dry absorber (SDA). The SDA is used to remove sulfur oxides from the flue gas produced during the combustion process in the boiler portion. In another prior art configuration, illustrated in FIG. 2 , which was not designed or initially provided with an SCR system, the flue gases from the boiler are conveyed through at least one flue to an air heater (in FIG. 2 , a tubular air heater) and then to downstream particle collection devices such as an electrostatic precipitator or ESP as shown, without any type of system to remove any LPA present in the flue gas from the flue gas stream. As a consequence of this, if an SCR were to be added, the LPA produced during the combustion process in the boiler could cause plugging, blockage and/or contamination of the catalyst passages, pores, or honeycomb structure present in the SCR catalyst blocks due to the presence of LPA.
[0032] As is noted above, the present invention addresses this problem through the use of least one LPA screen and/or at least one rotary valve located at a position in the flue conduit downstream of the boiler but upstream of the SCR and designed to remove at least about 50 percent of the LPA present in the flue gas stream. In one embodiment, as is illustrated in FIGS. 3 , 4 and 5 , the system 100 of the present invention comprises at least one LPA screen 102 and at least one rotary valve 104 that are positioned along a flue conduit 106 downstream of the boiler 108 but upstream of the SCR reactor or SCR 110 so as to remove at least about 50 percent of the LPA present in the flue gas stream. In one particular embodiment, the SCR unit 110 and an SCR outlet flue 112 therefrom are positioned in such a manner that the LPA collected from the flue gas prior to entry of the flue gas into the SCR 110 can be diverted and supplied to the SCR outlet flue 112 . As can be seen from FIGS. 3 , 4 and 5 , LPA screen 102 is provided at any suitable incline so as to cause LPA impacting LPA screen 102 to fall
[0033] As can be seen in FIGS. 3 , 4 , 5 and 6 , there can be multiple conduits 106 that transport flue gas from boiler 108 to SCR 110 . In this case, each conduit 106 has a LPA screen 102 and at least one rotary valve 104 as described above. As can be seen in FIG. 4 , each rotary valve is connected to a hopper designed to funnel LPA to a respective rotary valve. In either of these embodiments, the SCR outlet flue, or flues, 112 is/are designed to transport the SCR-treated flue gas and “added” LPA to additional downstream systems and/or environmental controls (e.g., an air heater, an SDA, or a baghouse, precipitator or other particle control device).
[0034] In another embodiment, the at least one LPA screen 102 can be eliminated from the system of the present invention in the instance where the flue conduits that transport the flue gas from the boiler to the SCR are designed in such a manner as to contain a reduced velocity zone. The reduced velocity zone is an area in the flue conduit where the flue conduit size is altered in such a manner as to result in a sufficient reduction in the velocity of the flue gas thereby causing the LPA present in the flue gas to “fall out” and collect in the hopper so that it can be conveyed therefrom via the one or more appropriately positioned rotary valves. This embodiment is illustrated in FIG. 6 where system 200 according to the embodiment comprises an inlet flue conduit 202 that supplies flue gas to a low velocity area 204 having a cross-section and/or volume that is sufficiently larger than conduit 202 so as to cause a suitable reduction in flue gas velocity, thereby resulting in the “fall out” of a suitable amount of LPA. In the embodiment of FIG. 6 , the SCR is split into two sections, sections 206 and 208 , placed on either side of an LPA collection area 210 located therebetween. As can be seen in FIG. 6 , low velocity area 204 (which is also an LPA collection area) contains at least one rotary valve 212 connected thereto. As can be seen in FIG. 6 , each rotary valve 212 is positioned at a hopper designed to funnel LPA to a respective rotary valve 212 . As with the other embodiments of the present invention the one or more rotary valves 212 are designed to convey collected LPA and “add” the LPA back into the flue gas after the flue gas is treated in the SCR and exits the one or more SCR sections via flue conduit 214 . The flue gas is then permitted to travel on to additional downstream systems and/or environmental controls (e.g., an air heater, an SDA, or a fabric filter, precipitator or other particle control device).
[0035] A non-limiting example of a reduced velocity embodiment would involve a flue gas stream that has a speed of about 50 feet per second after exiting the boiler, where such a flue gas stream is then slowed down by way of supplying the flue gas to a flue conduit having a larger cross-sectional area. This in turn causes at least about 50 percent of the LPA present in the flue gas stream to “drop out” due to the reduced flow speed that occurs when the flue gas travels from a high flow velocity area to a lower flow velocity area. In this embodiment the area in the flue conduit with the larger cross-sectional area further comprises one or more rotary valves designed to collect and supply the LPA to a conduit downstream of the SDA so that the LPA can be collected at a suitable point after bypassing the SDA. In another embodiment, this embodiment of the present invention is designed to remove at least about 75 percent, at least about 85 percent, at least about 95 percent, or even at least about 99 percent of the LPA present in the flue gas stream. Here, as well as elsewhere in the specification and claims, individual range limits can be combined to form new and/or non-disclosed ranges.
[0036] In another embodiment, the “velocity drop” achieved from the high velocity flue conduit to the low velocity flue conduit is at least about a 10 percent reduction in flue gas velocity. In still another embodiment, the “velocity drop” achieved from the high velocity flue conduit to the low velocity flue conduit is at least about a 20 percent, at least about a 30 percent, at least about a 40 percent, or even at least about a 50 percent reduction in flue gas velocity. Here, as well as elsewhere in the specification and claims, individual range limits can be combined to form new and/or non-disclosed ranges. If desired, this embodiment of the present invention can further include a LPA screen. Regarding the LPA screen of either embodiment of the present invention, such a screen can be made from any suitable material that can withstand exposure to the conditions typically found in the flue gas stream as it exits the boiler. Suitable materials from which a LPA screen, or screens, can be formed from include, but are not limited to, one or metals, one or more metal alloys, one or more ceramic compositions, or any suitable combination of two or more thereof. In one embodiment, the LPA screen of the present invention is formed from a mesh. In another embodiment, the LPA screen can be a plate structure in which suitably sized openings are formed therein. In either embodiment, the opening in the LPA screen should be sized in such a manner so as to prevent the passage there through. In one embodiment, the openings in an LPA screen, or LPA plate, of the present invention have a cross-sectional area of no more than about 38.5 mm 2 , no more than about 28.3 mm 2 , no more than about 19.6 mm 2 , or even no more than about 12.6 mm 2 . In still another embodiment, any LPA screen of the present invention can be replaced by multiple LPA screens that are arranged in downstream from one another. In this embodiment, each successive LPA screen would contain smaller openings there through so as to progressively and selectively remove LPA from a flue gas stream prior to entry of the flue gas stream to an SCR.
[0037] The flue gas static pressure upstream of the SCR (and thus at the inlets of the rotary valves on the hoppers on the inlet flues) will be higher than the flue gas static pressure on the downstream side of the SCR at the discharge (and thus at the outlets of the rotary valves connected to the outlet flues), due to the pressure drop through the SCR catalyst modules and associated flues. Rotary valves are thus used in the present invention because they are able to transport material between regions at different pressures. The rotary valves utilized in conjunction with the present invention are known in the art and, as such, an exhaustive discussion of same and their principles of operation herein are omitted for the sake of brevity. A suitable example of a rotary valve that can be used in conjunction with the present invention is a bottom discharge type rotary valve, available from Ricon Engineers, 6-A, Archana Industrial Estate, Opp. Ajit Mill, Rakhial, Ahmedabad—380023, Gujarat (INDIA).
[0038] The present invention is advantageous in that it is applicable to installations with existing SCRs (retrofits) and new SCRs. Additionally, the present invention can be applied to plants that utilize biomass as a fuel source. In one embodiment, implementation of the present invention can be accomplished in a cost-effective manner utilizing low cost hardware designed to remove any large particle ash (LPA) that is present in a flue gas stream prior to SCR treatment. The present invention also does not affect the current design of boilers and SCRs.
[0039] While specific embodiments of the present invention have been shown and described in detail to illustrate the application and principles of the invention, it will be understood that it is not intended that the present invention be limited thereto and that the invention may be embodied otherwise without departing from such principles. In some embodiments of the invention, certain features of the invention may sometimes be used to advantage without a corresponding use of the other features. Accordingly, all such changes and embodiments properly fall within the scope of the following claims. | The present invention relates generally to the field of emission control equipment for boilers, heaters, kilns, or other flue gas-, or combustion gas-, generating devices (e.g., those located at power plants, processing plants, etc.) and, in particular to a new and useful method and apparatus for preventing the plugging, blockage and/or contamination of an SCR catalyst. In another embodiment, the method and apparatus of the present invention is designed to protect an SCR catalyst from plugging and/or blockage from large particle ash that may be generated during combustion. | 1 |
BACKGROUND OF THE INVENTION
This invention relates to techniques for feeding seed cotton bales or modules to cotton ginning apparatus. More particularly, this invention relates to techniques for feeding modules which have become contaminated with water prior to processing.
Cotton harvesting and processing have progressed from labor-intensive operations to highly mechanized operations which generally include the steps of harvesting, compressing the harvested bolls into bales or modules, and feeding the modules through pronged feed rollers so that the fibers are dislodged from the module and may be conveyed by a conveyor belt to the gin equipment.
It is not uncommon for the modules to be stored outdoors on slabs or on the ground in the fields prior to transportation to the feeders. As a result of such storage, it is also not uncommon for modules to be contaminated with water along a bottom layer or stratum and that layer may extend into the module for up to about 12 inches.
Modules being fed into feeders must be closely inspected to determine whether or not the module is contaminated. If modules are seriously contaminated, those modules would be diverted to an area adjacent the cotton gin, where workmen using pitchforks will break away the contaminated cotton from the module to leave the contaminated cotton in its compressed condition. The seed cotton thus removed from the module is picked up by a telescoping vacuum tube and is fed to the cotton gin. The contaminated remnants of each module must then be removed by front end loaders or the like. If contaminated modules are accidentally or deliberately delivered to the feeder, the ginned cotton will be of inferior quality.
SUMMARY OF THE INVENTION
This invention provides a technique for feeding only the uncontaminated portion of a module to a cotton gin while conveying a contaminated face stratum to a disposal area where the contaminated cotton may be dried or used as livestock feed. According to this invention, a seed cotton module having a water-contaminated face stratum is conveyed toward a plurality of powered rotary fiber release rolls which are mounted at one end of a tunnel-like frame. The position of the group of feed rolls is adjusted with respect to the contaminated module so that only that portion of the module which is uncontaminated is contacted by the rotary fiber release rolls. The contaminated stratum of the module is conveyed under the lowermost rotary fiber release roll and further conveyed to a disposal station. The released uncontaminated seed cotton is conveyed to the cotton gin.
According to one aspect of this invention, the apparatus comprises a tunnel-like frame having a plurality of powered, rotary, fiber release bodies fixed to one end of the frame and defining a fiber release zone. A conveyor having a conveyor surface for transporting a water-contaminated seed cotton module toward the zone generally defines the bottom of the tunnel-like frame. The frame is pivotally mounted with respect to the conveyor at a location spaced from the fiber release bodies and the end of the frame which mounts the fiber release bodies is connected to powered rams so that the fiber release bodies may be raised to a predetermined level above the conveyor to establish a space which generally corresponds to the vertical extent of the contaminated face stratum of the module.
According to another aspect of the present invention, the elevation of the conveyor may be lowered relative to the release bodies to establish the spacing so that the contaminated face stratum is free to pass beneath the release bodies.
According to a further aspect of the present invention, the conveyor may be hinged so that the end adjacent the fiber release bodies may be adjustably fixed in a position which establishes the predetermined vertical spacing beneath the lower one of the fiber release bodies. In this instance, feed to the release bodies is assisted by a gravitational component on the module.
According to a still further aspect of the present invention, the lowermost powered rotary fiber release body may be pivotally linked to the penultimate body so that the lowermost body may be moved in a clockwise or counterclockwise direction with respect to the penultimate body and then fixed in an adjusted position which will establish the required vertical spacing between the lowermost release body and the conveyor surface.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an isometric view of the module feeding apparatus according to this invention;
FIG. 2 is a vertical, longitudinal cross section through the apparatus, the plane of the section being indicated by the line 2--2 in FIG. 1;
FIG. 3 is a cross-sectional view, similar to FIG. 2 but showing the forward end of the frame and the associated module feed rollers in an upwardly pivoted position;
FIG. 4 is an end view of the apparatus, with portions being omitted for clarity;
FIG. 5 is an enlarged, transverse section showing parts of the module feed rollers, portions being broken away for clarity;
FIGS. 6 and 7 are detail sections, the plane of the sections being indicated by the lines 6--6 and 7--7 in FIG. 5;
FIG. 8 is a view similar to FIG. 2 but showing a further aspect of the invention; and
FIG. 9 is a view similar to FIG. 2, but showing a still further aspect of the invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings, and particularly to FIGS. 1 and 2, a module feeder 10 according to one aspect of this invention comprises a housing 12 having an open mouth 14 at one end and a closed shroud 16 at its other end. The housing 12 includes a top wall 18, side walls 20 and 22, and the shroud 16. The shroud 16 is defined by the side walls 20 and 22 and end wall 24 and a sloping top wall 26.
The end of the housing 12 having the open mouth 14 is pivotally mounted on a pair of oppositely disposed hinges 28 mounted on vertical supports 30.
The other end of the housing 12, i.e., the closed end, is mounted on a pair of hydraulically operated lifting jacks 32 so that the entire housing 12 may be pivotally raised or lowered about the hinge connections 28.
The bottom of the housing 12 is open and the housing 12 is positioned over a module conveyor 34, which is adapted to convey a module 36 of compressed seed cotton into the mouth 14 of the housing 12.
Fixed to upper and lower horizontal framing members 38 and 40 of the housing 12 are a pair of parallel inclined beams 42 which carry journal bearings 44 (FIG. 5) in a bearing housing portion 46 of each side wall 20 and 22.
As may be seen in FIGS. 4 and 5, the bearings 44 carry journal portions 48 of six cross shafts 50, each having a sheave wheel 52 at one end thereof. All of the sheave wheels are driven by an electric motor 54 through belts 56 and 58 and additional sheave wheels 60 and 62.
Axially slidable but nonrotatable on the intermediate portion of each cross shaft 50 are a plurality of breaker/feeder bodies 64 and 66 each having four lobes 68. The bodies 64 and 66 are separated by rectangular spacers 70 loosely received on the shafts. The bodies are of hollow construction, with edge walls 72 forming openings 74 for admission into the interior of the body of coiled springs 56, each with end projections 78 and 80. Corresponding lobes 68 of each body 64 and 66 are aligned in the assembly and perforated to receive rods 82 which extend through and support the intermediate coils of the springs 76. As assembled, the inner ends 78 of the springs bear against the shaft spacers 70 and the outer ends 80 project approximately radially through the openings 74 for engaging the module 36 to remove material therefrom, as will be explained. The rods 82 are held in place by cotter pins 84 which are easily removable for withdrawal of the rods 82 and release of the breaker springs 76 for repair or replacement, without removal of the main shaft 50 or the spacers 70. In order to facilitate this replacement process, alternate ones of the breaker/feeder bodies are circumferentially staggered so that any of the rods 82 and their supported springs may be independently removed.
If an uncontaminated module 36 is conveyed into the open mouth 14 of the module feeder by the module conveyor 34, the rotating feeder bodies 64 and 66 engage the end of the module 36. When the rotating feeder bodies 64 and 66 engage the end of the module, material is released from the module, as is shown in FIG. 2, and propelled by the outer ends 80 of the coil springs 76 so that the material drops onto a transverse conveyor belt 86 to be conveyed to the cotton gin for further processing.
If the module 36 is contaminated by moisture, thus providing a contaminated layer 88 as is shown in FIG. 3, the lifting jacks 32 are actuated to pivot the housing 12 about the hinges 28, to thereby raise the elevation of the breaker/feeder bodies 64 and 66. Thus, the lowermost breaker/feeder body is raised to a position where it will clear the contaminated layer 88 so that only uncontaminated material will be fed to the transverse conveyor 86. The contaminated layer is moved beneath the lowermost breaker/feeder body by the conveyor 34 and the contaminated layer 88 will be redirected by a deflector plate 90 to a transverse conveyor 92. The transverse conveyor 92 transports the contaminated cotton to a suitable disposal site for use as cattle feed and the like. To prevent any waste material from clinging to the return reach of the conveyor 34, a brush roll 94 is provided near the discharge end of the conveyor. It should be noted that a lower confining chamber 96 is stationary with respect to the housing 12 and includes a partition 98 which facilitates the separation of the layer 88 from the usable material. A flexible connection, such as a bellows 100, extends between the confining chamber 96 and the housing 12.
Referring now to FIG. 8, there is illustrated a breaker/feeder body arrangement which will permit the lowermost feeder body 64a-66a to clear the contaminated layer 88 by swinging the lowermost feeder body in a counterclockwise direction about an arc having a radius emanating from the axis of the penultimate feeder body. In this instance, the inclined beams 42a may be provided with a hinged connection 42b which will permit the lowermost breaker/feeder body 64-66a to be rotated to the position illustrated in phantom outline in FIG. 8 by a piston 106, which is pivoted to the housing 12. The feeder body may be locked in this position by the hydraulic cylinder 106 and/or a suitable mechanical lock (not shown).
According to a further aspect of this invention, the housing 14 may remain stationary while a forward end portion 34a of the module conveyor 34 is pivoted downwardly so the lowermost feeder body will clear the contaminated layer. Referring to FIG. 9, a forward section 34a of a module conveyor 34b is hinged at a pivot pin 110, while the other end of the section 34a is pivotally connected to a lifting jack 32a. Thus, the jack 32a may be lowered to slope the section 34a to its phantom outline position in FIG. 9 so that the contaminated layer 88 of the module 36 clears the lowermost breaker/feeder body. This arrangement is particularly advantageous in that a gravitational component aids in the feeding of the module 36 into the breaker/feeder bodies.
Although the preferred embodiments of this invention have been shown and described, it should be understood that various modifications and rearrangements of the parts may be resorted to without departing from the scope of the invention as disclosed and claimed herein. | A method and apparatus for separating an uncontaminated portion of a seed cotton module from a water-contaminated face stratum are disclosed. The technique includes conveying a contaminated cotton module toward a housing having a plurality of rotating fiber release bodies mounted therein. The housing and the conveyor are arranged for relative movement so that only the uncontaminated portion of the module is fed into the fiber release bodies while the contaminated face stratum passes beneath the bodies. The uncontaminated cotton is collected and conveyed to a cotton gin and the contaminated cotton is conveyed to a disposal location. | 3 |
TECHNICAL FIELD
This invention relates to a process for preparing a methyl phenol by rearranging a tertiary hydroperoxide in the presence of a primary hydroperoxide with a mineral acid and hydrogenating the primary hydroperoxide with a catalyst selected from the group comprising chromium, copper, palladium, platinum, nickel, ruthenium and rhodium in the rearrangement medium.
BACKGROUND OF THE INVENTION
Various methods of making methyl phenols are known in the art. One method consists of sulfonating toluene with sulfuric acid and fusing the sulfuric acid with sodium hydroxide at a high temperature to produce para-cresol and sodium sulfite as a by-product. Since toluene is a petroleum based raw material there is a strong incentive to find a less expensive method of producing a methyl phenol. Another drawback to the sulfonation process is the production of an inorganic by-product sodium sulfite which must be safely disposed of at an increased expense to the cost of production.
Another method of producing methyl phenol is known as the cymene process. This process consists of auto-oxidizing cymene to a tertiary hydroperoxide and rearranging the hydroperoxide to cresol and acetone. Unfortunately some of the methyl group is auto-oxidized and provides primary hydroperoxide. This has been found to decrease the overall selectivity to cresol. When the primary hydroperoxide is rearranged it produces formaldehyde and para-isopropyl phenol. The formaldehyde is found to condense with the cresol which further lowers the selectivity and complicates the isolation of the cresol. Thus it is apparent that before the primary hydroperoxide is rearranged it must be separated or destroyed.
One known method for removal of the primary hydroperoxide from the crude oxidate is by an extraction technique. This method comprises contacting the mixture of tertiary and primary hydroperoxide with an aqueous alkali metal hydroxide solution to form a caustic solution and then contacting the caustic solution with a water insoluble volatile organic solvent having a dielectric constant greater than 3 to form a solution of tertiary cymene hydroperoxide in the organic solvent and volatilizing the organic solvent to recover the tertiary cymene hydroperoxide. Using this method, it was found to be difficult to separate the hydroperoxides.
Another known method claims to selectively rearrange the tertiary hydroperoxide and thermally decompose the primary hydroperoxide. This method comprises subjecting a liquid oxidation product of cymene hydroperoxide to an acid catalyzed cleavage at a temperature of 60° to 90° C. until the concentration of cymene hydroperoxide in the liquid is 0.5 to 5 percent by weight. This solution is then neutralized with an alkali and thermally decomposing the hydroperoxide at a temperature of 100° to 250° C. This method creates an explosion hazard and the primary hydroperoxide is completely decomposed and cannot be recycled.
Still another known method claims to remove the primary hydroperoxide by converting it into starting material. This method comprises rearranging the hydroperoxide in the presence of mineral acid, neutralizing the rearrangeate and hydrogenating in a one or two step procedure. This presumably reduces the residual hydroperoxide to a benzyl alcohol. The benzyl alcohol is then converted into the parent alkylbenzene. A major disadvantage of this process is the requirement of the high temperatures during the hydrogenations.
An object of the present invention is to provide a process for preparing a methyl phenol at a low hydrogenation temperature resulting in a more economic process.
Another object of the present invention is to provide a process for preparing a methyl phenol in a manner which does not create an explosion hazard.
Another object of the present invention is to provide a process for preparing a methyl phenol of high purity with the added advantage of providing recycleable parent hydrocarbon.
A further object of the present invention is to provide a process for preparing a methyl phenol which minimizes or precludes inorganic by-products.
SUMMARY OF INVENTION
According to the present invention there is provided a process for preparing a methyl phenol from an alkyl benzene which comprises oxidizing an alkyl benzene having the general formula ##STR2## where R is a secondary alkyl group and n is an integer of 1 to 3, acid decomposing the oxidation product solution, hydrogenating the acid decomposition product in the presence of a hydrogenation catalyst with or without solvent and recovering the resulting methyl phenol of the general formula ##STR3## where n is an integer of from 1 to 3, from the hydrogenated solution.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Typical examples of the alkyl benzene include 3,5-dimethyl cumene, para-isobutyl toluene, 2,4,6-trimethyl cumene, 3,4-dimethyl cumene, 2,4-dimethyl cumene, ortho-cymene, meta-cymene and para-cymene, with para-cymene being preferred.
The alkyl benzene may be oxidized with air or molecular oxygen and the like according to the conventional oxidation method at atmospheric or higher pressures such as 1723.75 KPa.
The oxidation reaction of alkyl benzene may be carried out in the presence of or in the absence of oxidation catalysts represented from the group of water soluble metallo phthalocyanines, alkyl substituted phthalocyanines, polymer bound metal salts or quaternary ammonium halides.
The oxidation reaction temperature may range from about 80° to 200° C., preferably 90° to 115° C.
The oxidation product containing primary hydroperoxide and tertiary hydroperoxide is then acid decomposed with a solvent under conventional conditions in the presence of catalytic quantities of one or more mineral acids such as sulfuric, hydrochloric, perchloric and the like. The solvent is selected from one or more polar solvents such as methyl isobutyl ketone, acetone or 2-butanone.
The acid solution containing the decomposition product is hydrogenated in the presence of one or more hydrogenating catalysts.
The hydrogenating catalyst used in the hydrogenation reaction may be that used in the conventional hydrogenation reaction such as copper, chromium, ruthenium, rhodium, palladium, platinum, nickel or other metals having hydrogenation activities in composition thereof, with palladium being preferred. The hydrogenation catalyst may be unsupported or supported with carriers such as barium sulfate, asbestos, diatomaceous earth, alumina, activated carbon and silica, with activated carbon being preferred.
In the present invention, the pressure in the hydrogenation reaction is not critical and may range from about 0 to 689.5 kPa, with 310.275 KPa being preferred.
The temperature in the hydrogenation step is not critical and may range from about 0° to 200° C., with 25° to 50° C. being preferred.
The contact time of the hydrogenation catalyst will vary according to the particular catalyst selected. Preferred time is such that the hydrogenation is carried out until no more hydrogen uptake is observed.
After the hydrogenation step is completed, the reaction product can be neutralized by contacting with at least one base such as gaseous ammonia, ammonia hydroxide or an alkali hydroxide such as sodium hydroxide, potassium hydroxide or an alkali carbonate such as sodium carbonate and potassium carbonate, with gaseous ammonia being preferred.
After neutralization is completed the methyl phenol and the starting alkylbenzene are removed by distillation.
Typical examples of methyl phenols which are obtained by the process are 3,4-xylenol, 2,4,6-trimethyl phenol, 3,4-xylenol, 2,4-xylenol, ortho-cresol, meta-cresol and para-cresol.
The present invention can be carried out in a batch, semi-continuous and continuous process, preferably continuous.
Any reference to iodine number was determined by Method I as disclosed in Analytical Chemistry, Volume 36, No. 1, pages 194 and 195 (January 1964) incorporated herein.
All standards of measurement shall be expressed as parts by weight unless specified to the contrary.
The present invention will be described in more detail in the following examples. However, these examples are intended to illustrate the invention and are not to be construed to limit the scope of the invention.
EXAMPLE 1
Into a resin kettle equipped with an air powered stirrer, a reflux condenser topped with a gas inlet tube leading to a wet test meter, a thermometer and a sparge tube were placed 769 parts of para-cymene (which had been washed with sulfuric acid, 5 percent sodium hydroxide and water respectively), 15 parts of 75 percent solution of tertiary butyl peroxyisobutyrate and 101.6 parts of 2 percent sodium hydroxide. The mixture was heated to 95° C. with stirring as oxygen was bubbled in at 15 liters per hour. The pH of the aqueous phase was maintained between 9.5 and 10 by addition of 2 percent sodium hydroxide. After 14 hours of oxidation the iodine number of the organic phase was 22.7. The aqueous phase and the organic phase were separated and the aqueous phase was acidified to a pH of 1 with sulfuric acid and the solid filtered to yield para-isopropyl benzoic acid. The residual water was removed from the organic phase by azeotropic distillation at 9 torr. The dry oxidate (334 parts) was added in a thin stream to 0.4 part sulfuric acid in 276.8 parts of acetone at reflux. The reaction mixture was held at reflux for 13 minutes after addition was completed. The mixture was then cooled to room temperature with an ice bath. The reaction mixture was poured into a hydrogenation bottle which contained 4.5 grams of 5 percent palladium on carbon. The material was hydrogenated at 344.75 kPa of hydrogen at 45° C. for 45 minutes. The solutions were combined, neutralized with gaseous ammonia and filtered. The acetone was removed at atmospheric pressure by distillation.
The dark residue was vacuum distilled to yield 72 parts by weight of para-cresol and 614 parts by weight of para-cymene.
The remaining materials comprised 5 parts of para-isopropyl benzoic acid, 39 parts of acetone and 15 parts of residue.
The selectivity to para-cresol based on recovered para-cymene was 58 percent.
EXAMPLE 2
In a 300 cubic centimeter autoclave were charged 169 parts para-cymene (which had been washed with 2 percent sodium hydroxide), 6.0 parts of tertiary butyl hydroperoxide and 20.32 parts of 2 percent sodium hydroxide.
The reaction mixture was heated to 100° to 110° C. with stirring. The reactor was pressured to 1723.75 kPa with an oxygen-nitrogen mixture such that the percentage of oxygen in the head space did not exceed 4 percent. The aqueous phase was kept basic by periodic addition of 2 percent sodium hydroxide. The autoclave was set up so that the samples which were withdrawn for pH measurements could be returned. After 5 hours an iodine number of 26.2 was observed. The reactor was drained and the phases were separated. The aqueous phase was acidified with hydrochloric acid to pH 1 and para-isopropyl benzoic acid was filtered. The organic phase was azeotropically dried at reduced pressure. The total volume of oxidate (162.2 parts) was added to 0.235 part of sulfuric acid in 138.4 parts of acetone. The solution was refluxed for 23 minutes. The rearrangeate was immediately cooled in an ice bath to room temperature. The rearrangeate was poured into a Paar hydrogenation bottle which contained 2.8 parts of 5 percent palladium on carbon. The rearrangeate was hydrogenated for one hour at room temperature and 344.75 kPa of hydrogen. The hydrogenated solutions were combined and neutralized with gaseous ammonia. The solution was then filtered and the acetone was removed at atmospheric pressure by distillation. The organic phase was extracted with 264.46 parts of 6 percent potassium hydroxide. The aqueous phase was neutralized to pH 7 and extracted with ether. After drying with sodium sulfate the ether was evaporated and the residue was vacuum distilled to provide a para-cresol. The organic phase was vacuum distilled to provide para-cymene.
The yields on Example 2 were approximately 122.6 parts of para cymene, 18.8 parts of para-cresol, 0.8 part of para-isopropyl benzoic acid, 10.9 parts of acetone, 4.9 parts of residue from cymene distillation and 1.4 parts of residue from cresol distillation.
The selectivity to para-cresol based on recovered para-cymene was 49 percent.
EXAMPLE 3
In a 300 cubic centimeter autoclave were placed 168.5 parts of para-cymene (which had been washed with 2 percent sodium hydroxide), 6.0 parts of t-butyl hydroperoxide and 20.32 parts of 2 percent sodium hydroxide.
The reaction mixture was heated to 100° to 110° C. with stirring. The reactor was pressurized to 1723.75 kPa with an oxygen-nitrogen mixture such that the percentage of oxygen in the head space did not exceed 4 percent. The aqueous phase was kept basic by periodic addition of 2 percent sodium hydroxide. The autoclave was set up so that the samples which were withdrawn for pH measurements could be returned. After 5 hours an iodine number of 28.4 was observed. The reactor was drained and the phases were separated. The aqueous phase was acidified with hydrochloric acid to pH 1 and para-isopropyl benzoic acid was filtered. The organic phase was azeotropically dried at reduced pressure. The total volume of oxidate (167 parts) was added to 0.21 part of sulfuric acid in 138.4 parts of acetone. This solution was refluxed for 28 minutes. The rearrangeate was immediately cooled in an ice bath to room temperature. The rearrangeate was poured into a hydrogenation bottle which contained 2.8 grams of 5 percent palladium on carbon. The rearrangeate was hydrogenated for one hour at room temperature and 344.75 KPa of hydrogen. The hydrogenated solutions were combined and neutralized with gaseous ammonia. The solution was then filtered and the acetone was removed at atmospheric pressure by distillation. The organic phase was extraced with 264.43 parts of 6 percent potassium hydroxide. The aqueous phase was neutralized to pH 7 and extracted with ether. After drying with sodium sulfate the ether was evaporated and the residue was vacuum distilled to provide para-cresol. The organic phase was vacuum distilled to provide para-cymene.
The yields on Example 3 were approximately as follows: 119.3 parts of para-cymene, 18.1 parts of para-cresol, 5.1 parts of residue from cymene distillation, 1.5 parts of para-isopropyl benzoic acid, 1.8 parts of residue from cresol distillation and 9.7 parts of acetone.
The selectivity to para-cresol based on recovered para-cymene was 45 percent.
EXAMPLE 4
In a 300 cubic centimeter autoclave were placed 169 parts of para-cymene (which had been washed with 2 percent sodium hydroxide, 6.0 parts of t-butyl hydroperoxide and 20.32 parts of 2 percent sodium hydroxide.
The reaction mixture was heated to 100° to 110° C. with stirring. The reactor was pressured to 1723.75 kPa with an oxygen-nitrogen mixture such that the percentage of oxygen in the head space did not exceed 4 percent. The aqueous phase was kept basic by periodic addition of 2 percent sodium hydroxide. The autoclave was set up so that the samples which were withdrawn for pH measurements could be returned. After 5 hours an iodine number of 25.2 was observed. The reactor was drained and the phases were separated. The aqueous phase was acidified with hydrochloric acid to pH 1 and para-isopropyl benzoic acid was filtered. The organic phase was azeotropically dried at reduced pressure. The total volume of oxidate (162.2 parts) was added to 0.20 part of sulfuric acid in 134.45 parts of acetone. The solution was refluxed for 30 minutes. The rearrangeate was immediately cooled in an ice bath to room temperature. The rearrangeate was poured into a hydrogenation bottle which contained 2.8 grams of 5 percent palladium on carbon. The rearrangeate was hydrogenated for one hour at room temperature and 344.75 kPa of hydrogen. The hydrogenated solutions were combined and neutralized with gaseous ammonia. The solution was then filtered and the acetone was removed at atmospheric pressure by distillation. The organic phase was extracted with 264.46 parts of 6 percent potassium hydroxide. The aqueous phase was neutralized to pH 7 and extracted with ether. After drying with sodium sulfate the ether was evaporated and the residue was vacuum distilled to provide para-cresol. The organic phase was vacuum distilled to provide para-cymene.
The yields on Example 4 were approximately as follows: 129.6 parts of para-cymene, 17.2 parts para-cresol, 3.5 parts of residue from cymene distillation, 1 part of para-isopropyl benzoic acid, 1.8 part of residue from cresol distillation and 9.2 parts acetone.
The selectivity to para-cresol based on recovered para-cymene was 54 percent.
The results shown in Table I are those obtained in determining the purity of the para-cresol and recycleable starting material (para-cymene).
TABLE I______________________________________Recycle Recycle Cymene CresolNumber Purity Purity______________________________________0 95.9% --1 95.2 98%2 94.8 953 94.1 944 94.5 97______________________________________
While certain representative embodiments and details have been shown for the purpose of illustrating the invention it will be apparent to those skilled in this art that various changes and modifications may be made therein without departing from the spirit or scope of the invention. | A process for preparing a methyl phenol from a tertiary hydroperoxide in an oxidation product of an alkylbenzene of the general structural formula ##STR1## wherein R is a secondary alkyl group and n is an integer of 1 to 3, which comprises hydrogenating the oxidation product in the presence of a mineral acid medium with a hydrogenation catalyst. | 8 |
BACKGROUND
The present invention relates to a warhead charge device for ammunition cargo units such as missiles, cruise missiles, light assault weapons, etc. The device is arranged to carry liquid explosive, herein denoting viscous explosive such as explosive mixed into slurry.
The proposal of ammunition units of the said types—which are individually dedicated to specific types of targets—is already known, and can be generally referenced in applicable patent literature. Thus ammunition units exist that are effective against hard targets, and there are other ammunition units that are effective against soft targets, etc.
There is a general desire to reduce the assortment of ammunition cargo units, and for a proposal to enable such units to combat a wider range of target types. One and the same ammunition unit shall thus be deployable in different scenarios and situations with retained effectiveness in each type of scenario and situation. The purpose of the present invention is to resolve the above problem and to propose that the ammunition unit be designed to be adaptable to achieve optimal effect in each engagement situation. The adaptability involved shall be unequivocal and shall satisfy the stringent requirements pertaining to the handling and operation of the ammunition or devices in question, especially in the field. The present invention also resolves this problem.
SUMMARY
The main characteristic feature of the initially mentioned warhead charge device is that the device in question incorporates at least two confined spaces that are equipped to receive liquid explosive or components thereof, or have the capability to do this while the device is operating. Another characteristic feature is that there is an arrangement to enable the explosive, or components thereof, to be completely or partially transferred from at least the first confined space to the second confined space, or vice versa. In this context ‘arrangement’ denotes a mechanical arrangement, overpressure/underpressure, etc. The pressure in question can be generated by compressed gas or pyrotechnics, etc. The expression ‘arrangement’ shall thus be interpreted in its widest sense.
In one design it is proposed that the first confined space be arranged centrally in the device adjacent to a first layer (or jacket) for the first effect components that can be comprised of pellets or fragments of large dimensions. A second confined space can then form a ring-shaped space located partly outside the first confined space and partly adjacent to a second layer for other effect components in the form of pellets or fragments of small dimensions for example. The first layer can thereby be located inside the said ring-shaped space. Furthermore, in another design a second ring-shaped space can be located outside the first ring-shaped space. The second effect layer can also be located between the first and second ring-shaped spaces.
The arrangement mentioned above can incorporate a pump device that, subject to a control system, pumps the explosive from the first confined space to the second confined space or vice versa. In one design the first confined space can be divided into two chambers that in a first function stage of the device each contains a mutually compatible explosive component. These two components are mixable in the two chambers in a second function stage of the device by complete or partial elimination of the dividing wall between the chambers on the occasion of the said second function stage. The explosive components in the two chambers are distributed in mixed state to the said first or second ring-shaped space in the same way as in the case described above where the components are mixed from the beginning, whereby transfer or distribution is performed by the said arrangement or pump device.
Additional spaces can also be utilised, and in one design the compatible explosive components in an initial stage can be applied in the said two additional spaces. In a subsequent stage the explosive components with the aid of the said arrangement or pump device can be transferred from the two additional spaces to, for example, the said first and second confined spaces that are arranged with one or more different effect layers with large pellets/fragments, small pellets/fragments, etc.
Additional design versions of the present invention are disclosed in the subsequent Patent Claims.
The above proposals achieve an attractive device that meets the said adaptability requirements, and that enables the ammunition cargo unit to be optimised for different types of target such as those that can be combated with large pellets/fragments, those that can be combated with small pellets/fragments, those that can be combated with blast effect, those that can be combated with carbon fibre rods and/or incendiary and combustion sustaining agents, etc. Proven parts, such as pump devices, can be used for transfer or re-distribution of explosive or explosive components from a first confined space to a second confined space. Alternatively, the mixing function can be performed with the aid of initiators, detonators, etc. The use of proven parts enhances safety during handling and servicing, and prepares the way for reliable ammunition cargo devices,
DESCRIPTION OF THE DRAWINGS
A currently proposed design for a device as claimed in the present invention is described below with reference to the appended FIGS. 1–5 in which
FIG. 1 shows a longitudinal section partially illustrating a warhead charge device, applicable in a missile, cruise missile, etc, with a central cylindrically shaped confined space outside of which two ring-shaped spaces are arranged, in between which layers or jackets of pellets of different dimensions are located, and
FIG. 2 shows a longitudinal section partially illustrating an alternative design to that shown in FIG. 1 , where the explosive is arranged in binary mixable explosive units, whereas
FIG. 3 shows a longitudinal section of an overview of a warhead charge device applicable or incorporated in an ammunition cargo unit where a design as per FIG. 1 interacts with additional confined spaces for the explosive components, while
FIG. 4 shows a longitudinal section partially illustrating another design form of the warhead charge device, and
FIG. 5 shows a longitudinal section partially illustrating a warhead charge device that differs somewhat from the warhead charge device shown in FIG. 4 .
DETAILED DESCRIPTION
FIG. 1 shows an ammunition cargo unit symbolically designated 1 . The ammunition cargo unit can be of an already known type, and in this context reference is made to generally known missiles, cruise missiles, light assault weapons, etc. As the ammunition cargo unit as such is already well known it will not be described in any further detail herein. The warhead charge device comprises a first confined space 2 arranged in a cylindrical unit 3 that is elongated in the longitudinal direction of the ammunition cargo unit. Cylindrical unit 3 is located at the centre of device 1 with which it has a common longitudinal axis 4 . A first effect layer 5 is arranged outside the sidewall 3 a of unit 3 . This effect layer can be comprised of pellets of large dimension whereby the expression ‘large’ relates to pellets that in this context are considered to have a relatively large calibre. A second confined space 6 is arranged outside effect layer 5 . In FIG. 1 the pellets in effect layer 5 are designated 5 a. This second confined space is located in a first ring-shaped unit 7 , which means that the second confined space 6 is also ring-shaped or rotationally symmetrical in form. A second effect layer 8 is arranged outside the first ring-shaped unit 7 . This effect layer can be comprised of pellets 8 a of small dimension. ‘Small dimension’ here denotes pellet sizes that in this context are considered to have a small calibre. A second ring-shaped confined space 9 located inside a second ring-shaped unit 10 is arranged outside the second effect layer 8 or pellets 8 a. Thus confined space 9 is also ring-shaped. A characteristic of the three confined spaces 2 , 6 and 9 is that they have essentially mutually equal volumes.
As claimed in the present invention a liquid explosive 11 is initially located in confined space 2 . As claimed in the present invention the liquid explosive 11 can be re-distributed to either confined space 6 or confined space 9 . This re-distribution can be effected by an arrangement that can comprise an already known pump device 12 for pumping or transferring the liquid explosive. The intake pipe 12 a of pump device 12 is thereby connected to confined space 2 , and pump device 12 has two outlet pipes 12 b and 12 c that connect pump device 12 to confined spaces 6 and 9 . The pump device 12 is controllable via an already known method from a control unit 13 that can execute control signals to pump device 12 so that it pumps from confined space 2 to confined space 6 or 9 . The control signals are designated 13 ′ and 13 ″, and the arrangement for control of the pump can be effected using an already known method.
The arrangement described above thus enables different warhead effects to be triggered depending on the control signals from control unit 13 . In a first case the explosive 11 can be triggered when it is in confined space 2 . This results in a warhead function utilising pellets 5 a and 8 a, i.e. pellets of both dimensions. In a second case the pump 12 has pumped the explosive over to confined space 6 , and a triggering of the warhead in this case results in a warhead function utilising only the small dimension pellets 8 a. In a third case the pump 12 has pumped the explosive over to confined space 9 , whereby the warhead function comprises only detonation of the explosive with ensuing damage, i.e. no pellets are released when the warhead is initiated.
Triggering is effected by means of an initiation or detonation system that can be comprised of an already known type. The triggering function of the ammunition cargo unit can thereby be determined by a device 14 via which an initiator 15 for the explosive in confined space 2 , initiators 16 and 16 a for possible explosive in confined space 6 , and initiators 17 and 17 a for possible explosive in confined space 9 can be initiated depending on which confined space 2 , 6 or 9 the explosive 11 is located in when triggering occurs. The explosive can assume an initial location in confined space 2 , 6 or 9 and be redistributed by a pump device 12 to another of two or more confined spaces in accordance with a predetermined strategy or programme. It is perceived that the number of confined spaces can vary from 2, 3 or more spaces. It is also perceived that the warhead charge device can be equipped with different effect layers 5 , 8 , for example in the form of fragments, carbon fibre rods, incendiary and combustion sustaining agents, etc. Adapting the warhead charge device to the type of target in question can be performed on the ground by a programming or other setting procedure. Alternatively, programming can be effected on board the weapon platform (e.g. aircraft) carrying the device in question. Another alternative is for programming of the device for the relevant type of target to be performed via wireless link from the ground or from the cargo unit 1 carrying the device, etc.
FIG. 2 shows the warhead charge device 18 with the same basic design as that illustrated in FIG. 1 , but with the difference that the confined space 2 , i.e. cylindrical unit 3 in FIG. 1 , is subdivided into two chambers 2 ′ and 2 ″. The cylinder in this case is designated 3 ′. The explosive components are located in the two chambers from the beginning. The explosive components are compatible and can be mixed using an already known method before the warhead charge device is triggered. Components A and B can be separated by a dividing wall 19 or be pre-packed, using an already known method, in sealed packs that keep components A and B separate until a mixing function shall be performed. The dividing wall 19 can be comprised of material that self-destructs when actuated. Actuation can be effected when or before the device is used in the ammunition cargo unit 1 ′ in question. Alternatively, some form of initiation or detonation can be effected, for example via device 14 ′. This device actuates initiator 15 ′ which causes explosive components A and B to be mixed. After the said mixing, chambers 2 ′ and 2 ″ function as a single confined space as per FIG. 1 . Alternatively, components A and B can be mixed in a third confined space and subsequently be pumped back to their original chambers in mixed form.
FIG. 3 shows the basic design of the warhead charge device similar to the design illustrated in FIG. 1 , but with the difference that the explosive 11 (see FIG. 1 ) in the initial stage of the warhead charge device 18 ′ is not located in any of the mentioned confined spaces 2 , 6 and 9 . Instead, the explosive or explosive components A and B are located in two additional confined spaces 20 and 21 . In this design example there are two confined spaces containing explosive components A and B that are mutually compatible in accordance with the above. In this case the pump device 12 ′ operates with three outlet pipes 12 b ′, 12 c ′ and 12 d ′. The pump intake pipe in this case branches into two branch pipes 12 a ″ and 12 a ′″. These two branch pipes connect confined spaces 20 and 21 to the pump intake 12 a ′. In the present case the mixing of explosive components A and B takes place in the actual pump function effected by pump device 12 ′. Thus completion of warhead charge device 18 ′ involves actuation of pump device 12 ′ and the transfer of the mixed explosive components A and B from confined spaces 20 and 21 . Transfer is to one of the confined spaces 2 , 6 or 9 . It is also considered feasible to use only one additional confined space instead of two additional confined spaces 20 and 21 , in which case the single additional confined space shall contain ready mixed explosive. It is also considered that the volume of confined spaces 20 plus 21 shall essentially be equivalent to each of the confined spaces 2 , 6 and 9 . In other respects, reference is made to the above.
FIG. 4 shows an arrangement in which the explosive can be transferred between chambers 23 and 24 depending on which warhead effect is desired. The warhead charge device 18 ″ for an ammunition cargo unit illustrated in FIG. 4 thus comprises a cylindrical device 22 containing the two chambers 23 and 24 for the explosive. Chambers 23 and 24 are separated by a wall 25 that is arranged to be convex when viewed from chamber 24 and concave when viewed from chamber 23 . The wall incorporates an opening 25 a in which a plug 26 or equivalent is arranged. An effect layer 27 , comprising pellets 27 a in the case illustrated, is arranged outside chamber 23 , i.e. outside the cylinder wall section 22 a . Effect layer 27 can be configured in alternative ways as stated above. FIG. 4 also shows an overview outline of initiation or detonation devices 28 and 28 ′ arranged at each end surface 22 b of the cylinder. When actuating the device 28 in question with the explosive in chamber 24 the shape of wall 25 provides a modified shaped charge function, while initiation via 28 ′ with the explosive in chamber 23 provides a fragmentation function utilizing pellets 27 a . It is considered that alternative design forms can be arranged in this respect, and that the wall 25 can be designed as a piston or equivalent to enable a corresponding function to be obtained. In the FIG. other initiation or detonation devices are designated 28 ′.
In FIG. 5 the outside of cylinder 22 ′ interacts with effect layer 27 ′ along the entire length of cylinder 22 ′. Besides chambers 23 ′ and 24 ′, both filled with explosive, the said cylinder also incorporates an additional chamber 29 . Chambers 23 ′ and 29 are linked to each other via a duct 30 . Explosive 23 ′ can thus be transferred to chamber 29 . In the design example the said duct is in the form of a pipe whose longitudinal axis coincides with that of cylinder 22 ′ and the longitudinal axis 4 ′ of the ammunition cargo unit. In this case chambers 23 ′ and 24 ′ are separated by a dividing wall 25 ′ of similar design to wall 25 in FIG. 4 . In principle cylinder 22 ′ is separable from effect layer 27 ′ such that in a first actuation mode the warhead charge device 18 ′″ can be triggered with effect layer 27 ′ lying outside cylinder 22 ′, and in a second actuation mode the cylinder and effect layer are separated such that the mixed explosive can be triggered without the presence of any outer effect layer. Thus in FIG. 5 the binary explosive components A and B are mixable. Furthermore, there is a third component composition C in chamber 24 ′. In FIG. 5 there is an additional dividing wall 31 between chambers 24 ′ and 29 . In the present case chamber 24 ′ can be termed an intermediate chamber between chambers 23 ′ and 29 .
The designs illustrated in FIGS. 4 and 5 can be given (an)other function(s) depending on the choice of explosive components and their various interactions. Thus the arrangement provides a warhead with a selectable HE or shaped charge effect. The design as illustrated in FIG. 4 can thus have the following composition and function as described below.
The warhead 18 ″ comprises two chambers 23 and 24 of essentially equal volume separated by a shaped charge liner 25 with a central opening 25 a . One chamber 23 has an external effect or fragmentation layer 27 ′. The explosive A is in liquid form and can be transferred from chamber 23 to the other chamber 24 via opening 25 a in shaped charge liner 25 , or via an external pipe system that is not illustrated. Liquid explosive with an effect almost like HMX can thereby be used. An alternative is ADN dissolved in ethanol.
If the explosive is in chamber 23 when warhead 18 ″ is actuated the warhead will function as a fragmentation warhead in which the shaped charge liner contributes to the formation of fragments. If the explosive is in chamber 24 when the warhead is actuated it will function as a shaped charge warhead with minor fragmentation.
In an alternative design form, which is not illustrated, chamber 23 is divided into two separate reservoirs containing different (compared with the above) explosive components. The two explosive components are not explosive when in separate state. Only when they are mixed do they form an explosive substance. By varying the mixing ratio between the components the effect can be constantly varied from low to maximum within the limits at which the mixture can be detonated. The explosive can be transferred between the two reservoirs either before launch or while travelling to the target, using the methods described above. In other respects reference is made to the above concepts and ideas.
The design in FIG. 5 can also be described from another aspect compared with the above.
FIG. 5 also illustrates a warhead charge device 18 ′″ consisting of a solid explosive charge C with shaped charge liner 25 ″ and a through duct 30 . On each side of explosive charge C there is a chamber 23 ′ and 29 . Both these chambers have essentially equal volumes, and chamber 23 ′ contains liquid explosive A. The said liquid explosive can be transferred between chambers 23 ′ and 29 via duct 30 . If the liquid explosive is in chamber 23 ′ when the warhead is actuated it will function as a fragmentation warhead, and the shaped charge liner will contribute to some extent to the formation of fragments. If there is liquid explosive in chamber 29 when the warhead is actuated the warhead will function as a shaped charge warhead with fragmentation effect from fragmentation layer 27 ′.
As described above the method for transferring the liquid explosive can consist of a mechanical arrangement such as an electrical or pneumatic arrangement. Alternatively, a pressurised or pressure difference arrangement can be used that operates with an over-and/or under-pressure arrangement, or with a pyrotechnic arrangement for pressurisation, etc.
The present invention is not limited to the design examples illustrated above, but can be subjected to modifications within the framework of the subsequent Patent Claims and the invention concept. | A warhead charge device ( 18, 18′, 18″, 18′″ ) arranged to carry liquid explosive ( 11 ), and which device is for use in an ammunition cargo unit such as a missile. The device incorporates at least two confined spaces ( 2, 6, 9 ) equipped with or, while the function of the device is in operation, capable of receiving liquid explosive ( 11 ) or components thereof via a device such as a pump device arranged to transfer completely or partially the explosive or components thereof from at least the first confined space to the other confined space, or vice versa. | 5 |
BACKGROUND OF THE INVENTION
1. Field Of The Invention
The invention relates to radiation-curable urethane acrylates containing isocyanate groups and their use as coating compositions with a particularly good adhesion to the coated substrate.
2. Description Of The Prior Art
Coating compositions which can be cured by high-energy radiation have an advantage over thermosetting coating compositions because of the lower energy consumption for the curing and their higher rate of curing. Radiation-curable coating compositions can furthermore be applied without a solvent, any co-used reactive thinners which may be necessary being simultaneously co-polymerized. However, a disadvantage of radiation-curable coating compositions, in particular those based on ethylenically unsaturated acrylates, is the high volume shrinkage during curing. Due to this shrinkage, adhesion to the substrate, e.g. to metals (steel sheets, copper etc.) and certain types of wood, is often inadequate.
It was already known from DE-A 3,616,434 that radiation-curable binders cure to coatings which adhere well on difficult types of wood if the substrate has been coated beforehand with a primer of compounds containing isocyanate groups (adhesive base). The obvious disadvantage of this process, however, is an additional lacquering step for application of the primer. The known process of admixing a low amount of lacquer polyisocyanates to the binder has the disadvantage that after radiation curing the lacquer polyisocyanates remain free. These polyisocyanates then are bonded neither to the substrate nor the film and therefore are able to adversely influence the hardness of the film or leave the film. US-A 5,234,970 claims a composition comprising
a) a compound containing isocyanate groups and ethylenically unsaturated groups,
b) reactive (meth)acrylate thinners and
c) if appropriate photoinitiators.
The disadvantage of this composition is that the reactive thinners b) contain OH groups, so that the stability of the composition in storage is limited even without any contact with atmospheric humidity.
One object of the present invention is therefore to provide coating compositions which can be cured by radiation and do not have the disadvantages mentioned for the prior art.
It has been found that certain urethane acrylates which contain free isocyanate groups can be cured by UV radiation on the substrates which are difficult to coat, such as certain woods, plastics and metals, to give coatings which adhere well.
These coating compositions contain almost no hydroxyl groups, so that they display high stability in storage in sealed vessels.
SUMMARY OF THE INVENTION
The invention relates to radiation-curable coating composition containing:
a) 10 to 100 wt. % of a urethane (meth)acrylate which contains both (meth)-acryloyl groups and free isocyanate groups,
b) 0 to 90 wt. % of (meth)acrylates which contain (meth)acryloyl groups but no free isocyanate groups or any isocyanate-reactive groups, the wt. % under a) and b) adding up to 100 wt. %, based on the weight of a)+b), and
c) 0 to 10 wt. %, based on the sum of components a) and b) of a UV initiator for free radical polymerization.
The invention also relates to metal, plastic, film, wood, leather and mineral substrates coated with the above-mentioned radiation-curable coating composition.
DETAILED DESCRIPTION OF THE INVENTION
Compounds a) are prepared from monohydric alcohols containing (meth)acryloyl groups and di- or polyisocyanates. Preparation processes for urethane (meth)acrylates are known and are described e.g. in DE-A 1,644,798, DE-A 2,115,373 or DE-A 2,737,406. For the urethane (meth)acrylates according to the invention containing free isocyanate groups, the equivalent ratio of NCO groups to OH groups is 1:0.2 to 1:0.8, preferably 1:0.3 to 1:0.6.
Monohydric alcohols containing (meth)acryloyl groups are understood as including both esters, containing a free hydroxyl group, of acrylic acid or methacrylic acid with dihydric alcohols, such as 2-hydroxyethyl, 2- or 3-hydroxypropyl or 2-, 3- or 4-hydroxybutyl (meth)acrylate, and mixtures of such compounds. Monohydric alcohols containing (meth)acryloyl groups or reaction products substantially containing such alcohols, which are obtained by esterification of n-hydric alcohols with (meth)acrylic acid, are also possible. It is also possible to employ mixtures of different alcohols, so that n represents an integer or a fractional number from 2 to 4, preferably 3(n-0.8) to (n-1.2), preferably (n-1) mol of (meth)acrylic acid is employed per mol of the alcohols mentioned. These compounds or product mixtures include the reaction products of i) glycerol, trimethylolpropane and/or pentaerythritol, low molecular weight alkoxylation products of such alcohols (such as ethoxylated or propoxylated trimethylolpropane, for example the addition product of ethylene oxide on trimethylolpropane of OH number 550), or of mixtures of such at least trihydric alcohols with dihydric alcohols (such as ethylene glycol or propylene glycol), with ii) (meth)acrylic acid in the molar ratio mentioned.
These compounds have a number-average molecular weight Mn of 116 to 1,000, preferably 116 to 750, and more preferably 116 to 158.
Suitable di- or polyisocyanates include aromatic, araliphatic, cycloaliphatic, and aliphatic compounds, aliphatic compounds being preferred. Examples include butylene-diisocyanate, hexamethylene-diisocyanate (HDI), isophorone-diisocyanate (IPDI), trimethylhexamethylene-diisocyanate (2,2,4- and/or 2,4,4-trimethylhexa-methylene-diisocyanate), neopentyl diisocyanate, dicyclohexylmethane-diisocyanate or 4-isocyanatomethyl-1,8-octane-diisocyanate and derivatives of these diisocyanates containing with a urethane, isocyanurate, allophanate, biuret, uretdione and/or iminooxadiazinedione groups. Di- or polyiso-cyanates which contain urethane groups and are based on di- or polyisocyanates and dihydric alcohols are also suitable.
The curing (addition reaction) can be accelerated in a known manner by means of suitable catalysts, such as, tin octoate, dibutyltin dilaurate or tertiary amines.
To increase the stability of the coating compositions according to the invention (e.g. towards premature polymerization and storage), 0.01 to 0.3 wt. %, based on the total weight of the reactants, of polymerization inhibitors or known antioxidants can be added to the reaction mixture. Suitable such additives are described e.g. in “Methoden der organischen Chemie” (Houben-Weyl), 4th edition, volume XIV/1, p. 433 et seq., Georg Thieme Verlag, Stuttgart 1961. Examples which may be mentioned include phenols, cresols and/or hydroquinones and quinones.
In a preferred variant, an oxygen-containing gas, preferably air, is passed through the reaction mixture during the preparation in order to prevent undesirable poly-merization of the (meth)acrylates.
The components mentioned under b) are (meth)acrylates which contain (meth)-acryloyl groups but no free isocyanate groups nor any isocyanate-reactive groups. Such binders are described, for example, in P.K.T. Oldring (ed.), Chemistry & Technology of UV & EB Formulations for Coatings, Inks & Paints, vol. 2, 1991, SITA Technology, London p. 31-235. Examples which may be mentioned include urethane acrylates, certain polyester acrylates and certain polyether acrylates.
The binders according to the invention can also be employed in a form diluted by solvents. Examples of suitable solvents include acetone, 2-butanone, ethyl acetate, n-butyl acetate, methoxypropyl acetate or low molecular weight esters of (meth)acrylic acid. Such mono-, di- or oligoesters of (meth)acrylic acid are known compounds in coating technology and are called reactive thinners and, as compounds which polymerize in during curing, lower the viscosity of the non-cured coating. Such compounds are described in P.K.T. Oldring (ed.), Chemistry & Technology of UV & EB Formulations for Coatings, Inks & Paints, vol. 2, 1991, SITA Technology, London p. 237-235. Examples include the esters of acrylic acid or methacrylic acid, preferably acrylic acid, with mono-, di-, tri- and polyalcohols. Suitable monohydric alcohols (monoalcohols) include the isomeric butanols, pentanols, hexanols, heptanols, octanols, nonanols and decanols; cycloaliphatic alcohols such as isobomol, cyclohexanol and alkylated cyclohexanols and dicyclopentanol; aryl-aliphatic alcohols such as phenoxyethanol and nonylphenylethanol; and tetrahydrofurfuryl alcohols. Alkoxylated derivatives of these alcohols can furthermore be used.
Suitable dihydric alcohols (dialcohols) include alcohols such as ethylene glycol, propane-1,2-diol, propane-1,3-diol, diethylene glycol, dipropylene glycol, the isomeric butanediols, neopentylglycol, hexane-1,6-diol, 2-ethylhexanediol, tripropylene glycol, and alkoxylated derivatives of these alcohols. Preferred dihydric alcohols are hexane-1,6-diol, dipropylene glycol and tripropylene glycol.
Suitable triihydric alcohols (trialcohols) are e.g. glycerol, trimethylolpropane and alkoxylated derivatives thereof. Propoxylated glycerol is preferred.
Suitable polyhydric alcohols (polyalcohols) include pentaerythritol, ditrimethylolpropane or alkoxylated derivatives thereof.
All constituents of component b) must be free from groups which are reactive with NCO groups under the preparation and storage conditions. Based for example on hydroxyl groups this means that the OH content of b) should be less than 10 and preferably less than 5 mg KOH/g.
A photoinitiator component c) can be added for the curing by UV radiation. Examples include known initiators that can trigger a free radical polymerization after irradiation with high-energy radiation, including UV light.
Such photoinitiators are described, for example, in P.K.T. Oldring (ed.), Chemistry & Technology of UV & EB Formulations for Coatings, Inks & Paints, vol. 2, 1991, SITA Technology, London p. 61-325. Those initiators which contain no groups which are reactive towards isocyanate groups, for example benzil dimethyl ketal and bisacylphosphine oxides, are preferred.
The coating compositions according to the invention can be mixed with known additives. These include fillers, pigments, dyestuffs, thixotropic agents, leveling agents, matting agents or flow agents, which are employed in the conventional amounts.
The coating system according to the invention can preferably be applied via spray, casting or roller application.
The coating system according to the invention is used for coating wood, film, plastics, leather, mineral substrates, metals (such as metal sheets, which may also be pretreated, and copper, for example in the form of wires) and substrates which have already been lacquered or coated. Particularly good results compared with systems according to the prior art are obtained on metal substrates and woods such as teak and mahogany.
Curing of the coatings according to the invention is carried out:
1. Optionally by allowing added solvent to evaporate. This is carried out at room temperature, optionally elevated temperature, preferably up to 80° C. An increase in temperature may also be advantageous in order to obtain an even better adhesion of the coating composition to the substrate.
2. By UV curing, for which commercially available high- or medium-pressure mercury lamps are suitable; these lamps can also be doped by other elements and preferably have an output of 80 to 240 W/cm lamp length. Films with solid surfaces which can be handled are formed after UV curing.
3. Optionally by crosslinking the NCO-containing constituents by means of moisture or with reactive groups in the substrate. This can be carried out at room temperature or elevated temperature, advantageously at 60 to 150° C. If an after-treatment at elevated temperature is omitted, the final properties of the system are established only after some time, approx. 3 to 7 days.
EXAMPLES
1. Preparation of the Urethane Acrylates (Constituent a)
Urethane Acrylate A Containing Isocyanate Groups:
552.0 g Desmodur N 3600 (commercial product of Bayer AG, Leverkusen, polyisocyanate substantially containing HDI isocyanurates, NCO content: 23.4 wt. %, viscosity 1,200 mPa.s at 23° C.) were initially introduced into a reaction vessel. 1.6 g 2,6-di-tert-butyl-4-methyl-phenol were added. The solution was heated to 60° C. while passing air through and stirring. The heating source was removed and 116.0 g 2-hydroxyethyl acrylate were added dropwise such that the temperature was between 55 and 65° C. Thereafter, the reaction was continued at 60° C. until the NCO content was below 12.5%. The resulting product had a dynamic viscosity at 23° C. of 12 Pa.s.
Urethane Acrylate B Containing Isocyanate Groups:
418.4 g Desmodur HL (commercial product of Bayer AG, Leverkusen, polyisocyanate substantially containing TDI and HDI isocyanurates, NCO content: 10.5 wt. %, viscosity 2,200 mPa.s at 23° C. and 60% in butyl acetate) and butyl acetate at a 40% solids content in the product were initially introduced into the reaction vessel. 1.0 g 2,6-di-tert-butyl-4-methyl-phenol was added. The solution was heated to 60° C. while passing air through and stirring. The heating source was removed and 81.7 g 2-hydroxyethyl acrylate were added dropwise such that the temperature was between 55 and 65° C. Thereafter, the reaction was continued at 60° C. until the NCO content was below 5.0%. The resulting product had a dynamic viscosity at 23° C. of 22 Pa.s.
2. Constituent b)
Commercially obtainable compounds were used: Urethane acrylate C: Roskydal UA VP LS 2265 (Bayer AG Leverkusen aliphatic urethane acrylate free from reactive thinner, viscosity 800 mPa.s at 23° C.), OH content<5mg KOH/g. Urethane acrylate D: Roskydal® UA VP LS 2308 (Bayer AG Leverkusen, aliphatic urethane acrylate 80% in hexanediol diacrylate, Viscosity 34,000 mPa.s at 23° C.), OH content<5 mg KOH/g.
3. Mixing and application of the coatings:
Photoinitiator
Urethane (meth)-
(Meth)acrylates
(Ciba
acrylate containing
free from NCO
Spezialitäten-
NCO groups
groups (letter/
chemie) (type/
Example
(letter/parts by wt.)
parts by wt.)
parts by wt.)
1
A/100
—
Darocur 1173/3
2
A/50
D/50
Darocur 1173/3
3 (comparison)
—
D/100
Darocur 1173/3
4
A/50
C/50
Darocur 1173/3
5
B/70
C/30
Darocur 1173/3
6 (comparison)
—
C/100
Darocur 1173/3
The formulations according to the invention from examples 1 and 2 and comparison example 3 were knife-coated on to untreated steel sheets (Unibond WH/600/OC) in layer thicknesses of 50 μm. They were then cured by means of a high-pressure mercury lamp (80 W/cm lamp length) at a belt speed of 3 m/min. Scratch- and chemical-resistant coatings were formed. After 24 h, the adhesion to the substrate was determined by the cross-hatch/adhesive tape test.
Result:
Example 1: The lacquer adhered. No lacquer was detached from the steel sheet with the adhesive tape.
Example 2: The lacquer adhered moderately. Some lacquer was detached with the adhesive tape.
Example 3: The lacquer did not adhere. The lacquer was detached completely (comparison) from the sheet with the adhesive tape.
The formulations according to the invention examples 4 and 5 and comparison example 6 were knife-coated onto teak wooden boards in layer thicknesses of 50 μm. They were then cured by means of a high-pressure mercury lamp (80 W/cm lamp length) at a belt speed of 3 m/min. Scratch- and chemical-resistant coatings were formed. After 24 h the adhesion to the substrate was determined by the crosshatch/adhesive tape test.
Result:
Example 4: The lacquer adhered. No lacquer was detached from the wood with the adhesive tape.
Example 5: The lacquer adhered moderately to well. Some lacquer was detached with the adhesive tape.
Example 6: (Comparison) The lacquer adhered poorly. The lacquer was detached almost completely from the wood with the adhesive tape.
Although the invention has been described in detail in the foregoing for the purpose of illustration, it is to be understood that such detail is solely for that purpose and that variations can be made therein by those skilled in the art without departing from the spirit and scope of the invention except as it may be limited by the claims. | The invention relates to radiation-curable coating composition containing:
a) 10 to 100 wt. % of a urethane (meth)acrylate which contains both (meth)acryloyl groups and free isocyanate groups,
b) 0 to 90 wt. % of (meth)acrylates which contain (meth)acryloyl groups but no free isocyanate groups or any isocyanate-reactive groups,
the wt. % under a) and b) adding up to 100 wt. %, based on the weight of a)+b), and
c) 0 to 10 wt. %, based on the sum of components a) and b) of a UV initiator for free radical polymerization.
The invention also relates to metal, plastic, film, wood, leather and mineral substrates coated with the above-mentioned radiation-curable coating composition. | 2 |
[0001] This application claims priority from co-pending U.S. Provisional Application No. 60/424,486, filed Nov. 7th, 2002, the full disclosure of which is hereby incorporated by reference herein.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates generally to the field of oil and gas well services. More specifically the present invention relates to a connector assembly for a perforating gun that is quick, reliable, and simple to use.
[0004] 2. Description of Related Art
[0005] Perforating guns containing shaped charges are used for the purpose, among others, of making hydraulic communication passages, called perforations, in wellbores drilled through earth formations. These perforations hydraulically connect predetermined zones of the earth formations to the wellbore. Perforations are needed because wellbores are typically completed by coaxially inserting a pipe or casing into the wellbore where the casing is retained in the wellbore by pumping cement into the annular space between the wellbore and the casing. The cemented casing is provided in the wellbore for the specific purpose of hydraulically isolating from each other the various earth formations penetrated by the wellbore. Without perforations, the hydrocarbons entrained in the formations surrounding the wellbore could not flow into the wellbore.
[0006] Many different types of perforating guns exist, but most have the same basic components. Those components are, shaped charges, a gun tube, a gun body, a top sub or connector, a detonator, and a bottom sub. Typically the shaped charges are disposed within the gun tube, and the gun tube is inserted into the gun body. The top sub is attached to the upper portion of the gun body and connects the perforating gun to a means for raising and lowering the perforating gun into a wellbore. The bottom sub generally attaches to the lower end of the gun body. Often, the bottom sub houses the detonator within a recess located inside of its body.
[0007] When the perforating gun is situated in the portion of the wellbore where a perforation is desired, the shaped charges within the perforating gun are detonated. This in turn produces perforations through the cemented casing lining the wellbore and into the surrounding formation. As is well known in the art, each time a perforating gun is used to produce perforations inside of a wellbore, some of the components of the perforating gun are either expended or fully destroyed. Thus before perforating guns can be reused, they must be returned to the surface and refurbished to replace the parts destroyed or used up during the previous perforation. During its refurbishment the perforating gun usually must be disassembled and reassembled prior to its next deployment.
[0008] Part of the disassembly and reassembly process of the perforating gun involves disconnecting the perforating gun from its raising/lowering means; which is typically a wireline. The wireline is attachable to a cablehead, which provides the connection between the perforating gun and the wireline. Wirelines can also serve to provide a signal conduit from the surface to the perforating gun to actuate detonation of the shaped charges. Generally the wireline cablehead is affixed to the upper sub of the perforating gun and is detached during refurbishment of the perforating gun. Additionally, the upper sub is disconnected from the gun body when the expended portions of the perforating gun are replaced. Thus to help minimize the time and expense of refurbishing perforating guns between subsequent uses, it is important that disconnecting and reconnecting the upper sub to the gun body be quick, simple, and be capable of being done at or close to the wellbore.
[0009] Often, because of special or uniquely sized components used for a specific perforating application, the perforating gun must be transported to a central processing facility for refurbishment instead of the site where the perforations are performed, i.e. the field. Transportation to and from the field to a central processing facility can be financially expensive as well as costly from a lost time standpoint. On the other hand, if a perforating gun could be refurbished for reuse at a field location, the added expense and time of transportation to a central processing facility could be avoided.
[0010] Some examples of perforating guns having connection means can be found in Hromas et al., U.S. Pat. No. 6,098,716, Burleson et al. U.S. Pat. Nos. 5,778,979, 5,823,266, and 5,992,523, and Huber et al., U.S. Pat. No. 6,059,042. However each of these suffer from the drawbacks that they are complex and the connection mechanisms disclosed therein contain multiple moving parts. Additional components add complexity, which reduces reliability and adds capital and maintenance costs. Further, none of the above noted references appears to have the capability of being refurbished or modified in the field, which limits their application to single uses and reduces their flexibility of use.
[0011] Therefore, there exists a need for a device or system in connection with perforating guns that provides for a fast and simple method of connecting and disconnecting perforating guns from a wireline. Also the system should allow for the perforating guns to be prepared at a field site, provide for multiple gun lengths, minimize the time required to assemble the perforating gun assembly, and include a proven way of sealing the perforating guns from wellbore fluids.
BRIEF SUMMARY OF THE INVENTION
[0012] One embodiment of the present invention discloses a connection system for a perforating gun comprising a top sub formed to receive one end of the gun body of a perforating gun. Disposed on the outer surface of the gun body is a circumferential groove. A collet is securable to the top sub where the collet has at least one finger formed onto its body. The collet finger is produced to engage the gun body groove, which in turn connects the gun body to the top sub. Further included with the present invention is a cover sleeve that circumscribes the finger wedging the finger between the cover sleeve and the groove. Also included with the connection system of the present invention is a seal disposed between the top sub and the perforating gun.
[0013] A fastener, such as threaded bolt, screw, rivet, or pin, can be used to secure the collet and cover sleeve to the top sub. The cover sleeve should be freely slideable along the axis of the perforating gun and formed to simultaneously circumscribe the collet and the perforating gun. The magnitude of the inner diameter of the cover sleeve is substantially uniform along its axis up until it reaches a lip of the cover sleeve. The cover sleeve lip is located on the end opposite where the cover sleeve is attached to the collet. The lip protrudes inward toward the axis of the cover sleeve and axially contacts at least one finger.
[0014] An alternative embodiment of a connection system for a perforating gun comprises a top sub formed to receive one end of a gun body of a perforating gun. A groove is circumferentially disposed on the outer surface of the gun body. Also included is a cover sleeve attachably detachable to the top sub on one end and having an inwardly protruding lip on the other end. Mating threads on the cover sleeve and on the top sub can be used to secure the cover sleeve to the top sub. A ring is disposed within the groove having an outer diameter that is at least equal to the inner diameter of the lip. Thus upon attachment of the cover sleeve to the top sub, the lip engages the ring. The engagement of the lip to the ring secures the gun body to the top sub. The ring is comprised of at least two hemispherical sections.
[0015] One of the many features of the present invention involves providing a fast and simple method of connecting perforating guns. The present invention also provides for perforating guns to be assembled at field locations and allows for random length of gun hardware. Further, the time and expense required to assemble/reassemble perforating guns is reduced by utilization of the present invention.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0016] FIG. 1 illustrates a partial cross-sectional view of a perforating gun connection assembly having a split ring.
[0017] FIG. 2 depicts a cross-sectional view of a perforating gun connection assembly having a collet.
[0018] FIG. 3A illustrates a cross-sectional view of a collet.
[0019] FIG. 3B illustrates an axial view of a collet.
[0020] FIG. 4 illustrates a cross-sectional view of a gun body.
[0021] FIG. 5 illustrates a cross-sectional view of a cover sleeve.
[0022] FIG. 6A illustrates an axial view of a ring.
[0023] FIG. 6B illustrates a cross-sectional view of a ring.
DETAILED DESCRIPTION OF THE INVENTION
[0024] With reference to the drawings herein, a perforating gun quick disconnect system according to one embodiment of the present invention is illustrated in FIG. 1 . For purposes of reference, bottom or lower refers to portions of the perforating gun located closer to the bottom of the wellbore, whereas top or higher refers to portions of the perforating gun situated closer to the wellbore opening. In one embodiment of the invention as shown in FIG. 1 , a top sub 10 is secured to the upper end of a gun body 50 . Seals 16 are provided on the outer radius of the top sub 10 and contact the inner radius of the upper section of the gun body 50 .
[0025] In the embodiments illustrated in FIGS. 1 and 2 , the top sub 10 is substantially cylindrical with a varying diameter, and preferably with its diameter being largest at its mid-section. With regard to the embodiment of FIG. 2 , it is preferred that the diameter of the top sub 10 be substantially equal to the collet base 41 . Just below the top sub 10 mid-section, its diameter reduces to form a shoulder 12 on which the collet base 41 is secured. An annular retainer 25 is attachable to the lower portion of the top sub 10 . It is preferred that the outer radius of the upper section of the retainer 25 be substantially the same as the inner radius of the collet fingers 42 . However, the radius at the lower section of the retainer 25 should be smaller than the radius of the collet fingers 42 . The reduced diameter along the lower section of the retainer 25 creates an annular space between the collet fingers 42 and the retainer 25 . That annular space should be formed such that it is capable of accommodating the upper portion of the gun body 50 along a portion of its lenght.
[0026] In an embodiment of the invention of FIG. 1 , a ring 30 is shown situated inside of a groove formed on the outer radius of the upper section of the gun body 50 . The ring 30 is preferably comprised of at least two hemispherical sections that when placed into the groove on the gun body 50 , the ring 30 can circumscribe substantially the entire diameter of the gun body 50 . Alternatively the ring 30 can be comprised of a single section that is press fit into the groove, or be of three or more sections. A cover sleeve 20 is shown circumscribing a portion of the top sub 10 and a portion of the gun body 50 . A cover sleeve lip 21 is formed on the bottom of the cover sleeve 20 having a radius substantially similar to the radius of the ring 30 . The cover sleeve lip 21 protrudes inward toward the axis of the cover sleeve 20 . The presence of the cover sleeve lip 21 adjacent the ring 30 can prevent the ring 30 from axially moving downward past the cover sleeve lip 21 . Threads 22 on the top of the cover sleeve 20 at its inner diameter are formed to mate with corresponding threads located on the outer diameter of the top sub 10 , thus providing a threaded connection between the cover sleeve lip 21 and the top sub 10 . It is important that the cover sleeve 20 inner radius be formed to allow it to easily axially traverse the gun body 50 , and yet leave only a small clearance between it and the outer diameter of the ring 30 .
[0027] Also included with this embodiment of the invention are a shaped charge 54 , a gun tube 52 , and a detonator 56 . The form and type of the top sub 10 , lower sub 11 , seals 16 , detonating cord 57 , gun body 50 , and detonator 56 can vary from those illustrated here without departing from the spirit of the present invention.
[0028] Assembly of the perforating gun of FIG. 1 generally involves first loading the gun tube 52 with shaped charges 54 using approved ballistic procedures. The detonator cord 57 and associated electrical wire 58 is routed along the path of the ignition points of the charges. The gun tube 52 is then inserted into the gun body 50 . The cover sleeve 20 is slid over the gun body 50 and the top sub 10 is inserted into an opening on the upper portion of the gun body 50 . The ring 30 is placed into the groove 51 on the gun body 50 . The presence of the ring 30 prevents the cover sleeve lip 21 from sliding above the ring 30 . Due to the small clearance between the inner diameter of the cover sleeve 20 and the outer diameter of the ring 30 , the ring 30 is secured in place inside of the groove 51 . It is to be understood that one skilled in the art can determine the clearance between the ring 30 and the cover sleeve 20 necessary to secure the ring 30 within the groove 51 .
[0029] To complete the assembly process, the cover sleeve 20 is slid upwards toward the top sub 10 and screwed onto the top sub 10 by virtue of the threads 22 disposed on the cover sleeve 20 and the top sub 10 . It is important that the sub seals 16 mate up against the inner diameter of the opening of the gun body 50 to prevent fluid leakage from the wellbore to the inside of the gun body 50 . As is well known, if wellbore fluids enter the inside of the gun body 50 , the fluids can either damage the shaped charges 54 before detonation, or cause the gun body 50 to split upon detonation of the shaped charges 54 .
[0030] Another embodiment of the present invention is illustrated in FIG. 2 . In this embodiment, the ring 30 and threads 22 of the embodiment of FIG. 1 , are replaced by a collet 40 and a collet fastener 46 . The collet 40 is formed to fit over a portion of the top sub 10 and is securable to the top sub 10 . The features of the collet 40 include a collet finger 42 with a collet finger insert 44 . The collet finger insert 44 is fashioned to fit within the groove 51 formed on the upper portion of the top sub 10 . Also included with this embodiment is a cover sleeve 20 having inner diameter that is sufficiently large to easily slide over the collet finger 42 . While the present invention can be equipped with one or more collet fingers 42 , it is preferred that the number of collet fingers 42 be six. Further, it is also preferred that the collet fingers 42 be radially displaced around the collet 40 with an equal distance between each adjacent collet finger 42 .
[0031] Assembly of the embodiment of the invention shown in FIG. 2 is much the same as the embodiment of FIG. 1 . The difference lies in how the gun body is secured to the top sub 10 . In the embodiment of the invention illustrated in FIG. 2 , the collet 40 is secured to the top sub 10 before insertion of the gun body 50 into the top sub 10 . Insertion of the gun body 50 into the top sub 10 positions the collet finger insert(s) 44 adjacent the groove 51 on the gun body 50 where the collet finger insert(s) 44 can then fit into the groove 51 . As can readily be seen from FIG. 2 , upon assembly of the present invention, the axis of the collet 40 should be substantially aligned with the axis of the gun body 50 .
[0032] Because the collet finger insert(s) 44 is designed to mate inside of the groove 51 , the distance from the collet axis to the collet finger insert(s) 44 is equal to the distance from the groove 51 to the collet axis. Since the outer radius of the gun body 50 is greater than the distance from the groove 51 to the collet axis, the collet finger insert(s) 44 must be urged axially outward before the gun body 50 is inserted into the top sub 10 . Application of a sufficient upward axial force to the gun body 50 will temporarily bend the collet finger insert(s) 44 outward; thus out of the way of the gun tube 50 . Radial displacement of the collet finger insert(s) 44 allows the gun tub 50 to fit inside of the top sub 10 . To ensure ease of use and a quick turnaround time, the force required to insert the gun body 50 within the collet finger(s) 42 , or retract the gun body 50 from the grasp of the collet finger(s) 42 , should not exceed approximately 50 pounds force. Thus material selection of the collet finger(s) 42 as well as the size of the collet finger(s) 42 is dictated by this requirement. It is believed that one skilled in the art can choose the proper dimensions and material of a collet finger(s) 42 without undue experimentation.
[0033] Once the collet finger insert(s) 44 are within the groove 51 , the cover sleeve 20 can then be slid upward such that the body of the cover sleeve 20 surrounds the collet finger(s) 42 and collet finger insert(s) 44 . The inner diameter of the cover sleeve 20 retains the collet finger insert(s) 44 within the groove 51 on the gun body 50 . The cover sleeve 20 can be secured to the collet 40 by a threaded fastener 46 . However any number of other attachment devices can be employed, such as rivets, pins, or a series of mating threads on the inner diameter of the cover sleeve 20 and the outer diameter of the collet 40 . Firmly securing the collet finger insert(s) 44 inside the groove 51 provides a connection between the top sub 10 and the gun body 52 . This in effect connects the perforating gun to the wireline.
[0034] The present invention could employ a single cover sleeve 20 in conjunction with a single groove 51 formed on the upper or the lower portion of the gun body 50 . This would result in a quick disconnect system for either the top sub 10 or the bottom sub 11 , but not both subs simultaneously. However, a cover sleeve 20 and groove 51 on both ends of the gun body 50 allows for quick and simple removal, as well as attachment, of both the top sub 10 and the bottom sub 11 from the gun body 50 . Thus, it is preferred that the grooves 51 be provided on the gun body 50 at both its upper and its lower end.
[0035] Assembly of a perforating gun could be done with a groove 51 far from either end, but this would require a long collet finger(s) 41 and an elongated cover sleeve 20 . Since a long collet finger(s) 41 or a long cover sleeve 20 can increase the time and effort required to assemble and disassemble the perforating gun, it is preferred that the groove 51 be positioned close to its associated sub.
[0036] One of the many advantages of the present invention is realized during disassembly of the associated perforating gun. Just as the perforating gun having the present invention can be quickly and easily assembled, it can also be quickly and easily disassembled. Once the shaped charges 54 have discharged and the perforating gun is removed from the wellbore, the collet fastener 46 can be removed and the gun body 50 can be detached from the top sub 10 . Detaching the gun body 50 from the top sub 10 of the present invention does not involve the use of tools but instead can be performed manually—simply by pulling the gun body 50 away from the top sub 10 . More importantly, this function can be done in the field, thus eliminating the need to transport the perforating gun to a central processing facility. A loaded perforating gun can then be reattached to the top sub 10 and the perforating process can be repeated immediately.
[0037] The material selection of the gun body 50 , ring 30 , and collet 20 is important. Due to the large impulse forces encountered during use by each of these components, they should be constructed of a material that does not easily yield, either momentarily or permanently. Even small amounts of yield during use can cause the gun body 50 to bond to the collet finger insert(s) 44 . Which is highly undesirable since quick disassembly is important when refurbishing perforating guns. The proper material of the gun body 50 , ring 30 , and collet 20 can be determined by one skilled in the art and without undue experimentation.
[0038] The bottom sub 11 of the embodiment of the present invention of FIG. 2 can be attached to the gun body 50 in much the same fashion as the top sub 10 . However, because of the detonator 56 , safety procedures typically require that the detonator 56 be connected while the detonator 56 is in a blast shield outside of the gun assembly. The detonator 56 is then connected to the detonating cord 57 .
[0039] One of the many advantages of the present invention is the efficient manner in which the perforating gun can be assembled and disassembled, either for its initial use or for subsequent uses. The present invention enables the assembly/disassembly of the perforating guns to be done at either a primary manufacturing site, or in a remote field site. Thus use of the present invention eliminates time wasted to transport perforating guns to a primary manufacturing site for processing, saves money associated with transporting perforating guns, and reduces the time and effort required to assemble/disassemble perforating guns, either in the field, or at a manufacturing facility. For example, the present invention allows the user the flexibility of forming the groove 51 onto the gun body 50 in the field with a lathe or other machining device. The gun body 50 with its newly formed groove 51 can then be attached to the top sub 10 , while still in the field, inserted into a wellbore, and have the shaped charges within the gun body 50 detonated. After the perforating gun is raised up and out of the wellbore, a new gun body 50 , with a newly formed groove 51 can be switched into the present invention and the perforating process repeated. This provides one example of how use of the present invention allows many functions to take place in the field and reduces the need for machining at a manufacturing site, which in turn reduces costs, effort, and time associated with transportation and engineering coordination.
[0040] A further advantage of the present invention is that the top sub 10 can be disconnected from the perforating gun without the need to disconnect the wireline. This not only saves time, but can reduce possible infield anomalies caused by mistakes in the attachment/detachment during use of the perforating gun. In addition to a cost and time savings, the present invention also is flexible in its application. Use of the present invention is not limited to a single perforating gun of a single length. Instead the present invention can be implemented on perforating guns of any length.
[0041] 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 are possible in the details of procedures for accomplishing the desired results. 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. | A connection system to be used in conjunction with a perforating gun comprising a top sub formed to receive one end of a gun body of a perforating gun, a circumferential groove disposed on the outer surface of the gun body, and a collet secured to the top sub. The collet has at least one finger that engages the groove. Engaging the groove with the at least one finger of the collect connects the gun body to the top sub. A cover sleeve is included that retains the finger in connective engagement with the groove. | 4 |
BACKGROUND OF THE INVENTION
The present invention is concerned with a component that functions with bulk acoustic waves, particularly a bandpass filter.
One filter technology that functions with acoustic waves is known as a thin film bulk acoustic wave resonator or FBAR, and another is a bulk acoustic wave filter, which is known as a BAW filter. Both of these filters can be implemented as bandpass filters by interconnecting different thin-film resonators (FBAR) built using FBAR technology.
BAW components have a multi-layer structure having a plurality of layers arranged one over the other. Here, it is possible to have a vertical structure consisting of a plurality of BAW resonators as is known and disclosed in U.S. Pat. No. 5,821,833, whose disclosure is incorporated herein by reference thereto.
FIG. 1A shows an exemplary BAW component having a resonator stack which includes a plurality of resonators arranged over one another.
A resonator that functions with bulk acoustic waves, for example a resonator R 3 A in FIG. 1A has a piezoelectric layer PS 3 , which is arranged between two electrode layers E 5 and E 6 . It is known that instead of only one piezoelectric layer, a layer sequence can also be used. The layers are deposited on a substrate TS one after another and structured into the resonators. As illustrated, the stack includes electrode layers E 1 and E 2 , which are on opposite sides of a piezoelectric layer PS 1 , and electrode layers E 3 and E 4 , which are on opposite sides of a piezoelectric layer PS 2 . The electrode layers, such as E 1 , E 2 , E 3 and E 4 , are structured in the lateral plane so that sub-electrodes E 11 and E 12 are formed from the layer E 1 ; sub-electrodes E 21 and E 22 are formed from the layer E 2 and sub-electrodes E 31 , E 32 , E 41 and E 42 are formed from the remaining two electrode layers. The sub-electrodes E 11 and E 21 lying over one another form together with the piezoelectric layer PS 1 lying therebetween a sub-resonator R 11 . Sub-resonators R 12 , R 21 and R 22 are built in a similar manner. Between the electrode layers E 2 and E 3 and layers E 4 and E 5 are coupling layer systems KS 1 and KS 2 , respectively, which systems are acoustically at least partially transmissive. These coupling layer systems along with sub-resonators, such as R 21 and R 22 arranged therebetween, guarantee an acoustic coupling in the vertical direction between the subresonators R 11 and R 12 in the vertical direction with the resonator R 3 A and the transmission of an electrical signal is possible from the sub-resonator R 11 to the sub-resonator R 12 in case of the galvanic isolation therebetween.
The sub-resonator R 11 is connected to a first electrical gate P 1 used to couple in an electrical signal. The sub-resonator R 12 is connected to a second electrical gate P 2 to couple out the electrical signal.
The electrical series connection of the acoustically coupled sub-resonators R 11 /R 21 and R 12 /R 22 of the two resonator stacks formed adjacent one another takes place by means of the continuously formed electrode layer E 5 .
The multi-layer structure shown in FIG. 1A in schematic cross-section is arranged on the substrate TS. It is known that a resonator stack can be arranged over a hollow space provided in the carrier substrate or over an acoustic mirror, such as AS.
It is known that the resonators and/or sub-resonators arranged over one another or adjacent to one another can be electrically connected to one another and, together, can provide a filter element or a filter circuit, particularly a bandpass filter. A bandpass filter of this sort can be used together with additional filters also in a duplexer.
In FIG. 1B , an exemplary known implementation of the electrical and acoustic connection via a middle electrode layer ME of two series resonators SR 1 and SR 2 arranged over one another is schematically illustrated in the left side of the Figure and are shown in a circuit diagram on the right side of the Figure.
In FIG. 1C , a circuit diagram on the left side of the Figure for a basic element of a ladder type filter with a series resonator SR arranged in a signal line and a parallel resonator PR parallel to a signal line is shown. On the right side of the Figure, the schematic design of such a basic element is shown in cross-section. The series resonator SR is arranged laterally adjacent to the parallel resonator PR.
In FIG. 1D , a T-element can be formed with: series resonators SR and SR 1 arranged adjacent to one another and a parallel resonator PR. These are shown in a circuit diagram on the left side of the Figure and shown in cross-section on the right side of the Figure. Also known is a filter structure shown in FIG. 1E on the left side, which consists of a plurality of interconnected T-elements. This filter structure is suited particularly to transmission of symmetrical or balanced electrical signals. The series resonators SR 11 , SR 12 , SR 13 and SR 14 are arranged in a first signal line. The series resonators SR 21 , SR 22 , SR 23 and SR 24 are arranged in a second signal line. The two signal lines are connected to one another using parallel branches which include at least two parallel resonators PR 1 , PR 2 and PR 3 , PR 4 . The resonators are arranged adjacent to one another and are illustrated in the left side of the Figure as a circuit diagram and have a schematic top view of the filter structure shown in the right side of FIG. 1E .
Series and/or parallel resonators can be connected, in each case, to an inductance, for example a bond wire, in series in order to increase the passband width. It is also possible in case of interconnection of a plurality of series resonators with a plurality of parallel branches to bridge some of the series resonators between the adjacent parallel branches or to omit parallel branches between two series resonators. Some of the resistors can be replaced, for example, with a capacitance, an inductance or an LC element. For subsequent adaptation of the static capacitance of a BAW resonator, for example improving the rejection band selectivity, a capacitor can be connected in parallel to it.
In a BAW resonator, preferably only one acoustic mode, which is a main mode, is excited which, however, is often coupled to additional, undesired, particularly lateral, acoustic modes. Due to this mode coupling, the emergence of the acoustic energy out of an active resonator region occurs, which leads to energy losses and, thus, to a high insertion loss in the signal to be transmitted. The localization of the acoustic wave in the active resonator region occurs, for example, through the attenuation of the excitation in the edge region of the BAW resonator. This can be attained through addition of an additional material frame in the edge region of the upper electrode of the resonator or also through a special electrode configuration with sides that do not run parallel to one another, as shown, for example, from the International Publication WO 01/06646, whose disclosure is incorporated herein by reference thereto.
In addition, it is known from International Publication WO 01/99276 A1 and U.S. Pat. No. 6,448,695 B2, which claims priority from the same British Application and whose disclosure is incorporated herein by reference thereto, that resonators that are arranged laterally adjacent to one another and electrically connected through a common electrode can be acoustically coupled additionally through a lateral acoustic mode. This additional acoustic signal path contributes, in this case, to a particularly efficient signal transmission between two resonators, and it is possible to attain a particularly low insertion loss in the signal.
Almost all of the previously known BAW resonators, particularly with ladder-type filter topologies, have in common that they do not satisfactorily fulfill the demanding requirements of mobile radio operators for rejection band selectivity. A problem which is not uncommon and which is difficult to solve in a BAW filter design is that of attaining a low insertion loss.
SUMMARY OF THE INVENTION
An object of the present invention is to specify a component that functions with acoustic waves which offers improved transmission characteristics.
One embodiment of the invention is a component that functions with bulk acoustic waves with a multi-layer structure, for example a resonator stack, which has a first electrode layer arranged above and a second electrode layer arranged below a piezoelectric layer arranged therebetween which together form a resonator layer region. It is also possible to arrange additional resonator layer regions formed in this manner in a resonator stack over one another. Here, all of the electrode layers are structured in the lateral plane so that there results per electrode layer at least two electrically isolated sub-electrodes. In each case, two sub-electrodes arranged over one another form together with the piezoelectric layer lying therebetween a sub-resonator. A number of the sub-resonators arranged laterally adjacent to one another corresponds to the number of sub-resonators resulting in a respective resonator layer region. According to the invention, at least two of the sub-resonators arranged in the resonator layer region are coupled acoustically by a lateral acoustic mode.
An embodiment of the invention is based on the effect of coupling different modes that can be excited in a BAW resonator of bulk acoustic waves, particularly the coupling between the main mode and the lateral mode, which effect had to be suppressed in most BAW applications known heretofore. The lateral acoustic coupling is used according to the invention for the first time instead of an electrical connection, while the acoustic coupling and the component known, for example, from International Publication WO 01/99276 and U.S. Pat. No. 6,448,695 B2, represent an additional signal path running in parallel to the electrical signal.
The component according to the invention fulfills preferably the function of a filter, particularly a bandpass filter. In an advantageous variant of the invention, one of the resonator layer regions is divided into two sub-resonators of which one sub-resonator is connected with respect to a first reference potential and the other sub-resonator with respect to the second reference potential, the two reference potentials differing from one another. In an advantageous manner, a component according to the invention fulfills, in such an embodiment, in addition to the function of a bandpass filter, the function of an “acoustic transformer” for decoupling input and output signals.
It is also possible that one of the acoustically laterally coupled sub-resonators is connected with respect to the first reference potential and the other sub-resonator between two signal lines. In this configuration, a component according to the invention makes it possible to build a balanced to an unbalanced functionality or a balun functionality that requires little space.
The acoustically coupled sub-resonators of a resonator layer region can also be connected, in each case, between two signal lines of the component fed from a symmetrically formed first electrical gate to a likewise symmetrically formed second electrical gate. Here, it is possible that the sub-resonators that are acoustically coupled in the lateral direction are arranged in two different signal paths or parallel to different signal paths. Another possibility consists in that one of the acoustically coupled sub-resonators is arranged in one signal path and the other sub-resonator parallel to another signal path. Different signal paths can be formed, for example, as a transmit and a corresponding receive path of a mobile radio system whose filters are realized on the component according to this invention.
Another advantage of a component according to the present invention consists in that through the acoustic coupling of the resonators, additional pole points arise in the transfer function of the component, which contribute in case of a suitable design to the improvement of the signal suppression in the rejection band.
In case of purely acoustic coupling of the resonators within a filter circuit, filter transfer functions can be obtained with a steep edge slope, high rejection band suppression, low insertion loss and low ripple in the passband. Moreover, using acoustic coupling of the resonators, the connecting technology that is needed otherwise for electrical connection can be spared. A component according to the invention can be operated in a balanced/balanced manner, an unbalanced/unbalanced manner or as a balun and can act, moreover, in an impedance transforming manner.
The invention is compared hereafter with components known from the prior art and explained in greater detail using schematic figures which are not true to scale.
Other advantages and features of the invention will be readily apparent from the following description, the claims and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A is a schematic cross-sectional view of a known BAW component with resonators arranged over one another;
FIG. 1B , on the left side, has a schematic cross-sectional view of a known BAW component with series resonators arranged over one another and, on the right side, has a circuit diagram of the component;
FIG. 1C , on the left side, has a circuit diagram of a known BAW component with resonators arranged adjacent to one another of a filter basic element and is shown in a schematic cross-sectional view in the right side of the Figure;
FIG. 1D , on the left side, is a circuit diagram of a known BAW component with resonators arranged adjacent to one another of a T-element and, on the right side, has a schematic cross-sectional view of the component;
FIG. 1E , on the left side, is a circuit diagram of another known BAW component for transmitting a balanced signal, with resonators arranged adjacent to one another and is a schematic top view of the component shown on the right side of the Figure;
FIG. 2A is a schematic cross-sectional view of a BAW component with resonators arranged adjacent to one another, electrically isolated from one another and coupled acoustically through a lateral acoustic mode in accordance with the present invention;
FIG. 2B is a schematic plan view of a BAW component according to FIG. 2A ;
FIG. 2C is a schematic cross-sectional view of a BAW component with a plurality of resonator layers with sub-resonators in each resonator layer region arranged adjacent to one another and being electrically isolated from one another and coupled acoustically through a lateral acoustic mode;
FIG. 3A is a circuit diagram of a known BAW component with a bridge connection of the resonators;
FIG. 3B is a schematic top plan view of the BAW component according to FIG. 3A ;
FIG. 4A is a circuit diagram of a BAW component with a bridge connection of the acoustically coupled resonators;
FIG. 4B is a schematic top view of the BAW component of FIG. 4A ;
FIG. 5A is a circuit diagram of a BAW component with a bridge connection of the acoustically coupled resonators;
FIG. 5B is a schematic top view of the BAW component of FIG. 5A ;
FIG. 6 is a schematic cross-sectional view of a BAW component with a resonator stack with a bridge connection of the sub-resonators;
FIG. 7A is a circuit diagram of a BAW component with a plurality of series-connected bridge connections of the sub-resonators;
FIG. 7B is a schematic cross-sectional view of the BAW component with the resonator stack with a cascaded bridge connection of the sub-resonators according to FIG. 7A ;
FIG. 8A is a circuit diagram of a BAW component with acoustically coupled resonators which are arranged in two different signal paths;
FIG. 8B is a circuit diagram of another BAW component with acoustically coupled resonators which are arranged in two different signal paths;
FIG. 8C is a circuit diagram of a third BAW component with acoustically coupled resonators which are arranged in two different signal paths;
FIG. 9A is a schematic cross-sectional view of a BAW component with a resonator stack, with electrically isolated sub-resonators which are coupled acoustically through coupling resonators;
FIG. 9B is a circuit diagram of the BAW component according to FIG. 9A ;
FIG. 9C is a schematic cross-sectional view of an advantageous exemplary embodiment of a BAW component with a resonator stack, with sub-resonators which are coupled acoustically through the coupling resonators;
FIG. 10A is a circuit diagram of a BAW component with a ladder-type structure with acoustically coupled series resonators;
FIG. 10B is a schematic cross-sectional view of a BAW component with a ladder-type structure with acoustically-coupled series resonators arranged in the resonator stack on the left side of the Figure and a circuit diagram of the component on the right side of the Figure;
FIG. 10C is a schematic cross-sectional view of another exemplary embodiment of a BAW component with acoustically coupled, through lateral acoustic mode, series and parallel resonators;
FIG. 10D is a circuit diagram of the BAW component according to FIG. 10C ;
FIG. 11 is a schematic plan view of a BAW component with a ladder-type structure according to FIG. 10A with series resonators arranged laterally adjacent to one another and acoustically coupled with one another;
FIG. 12A is a circuit diagram of a BAW component with a ladder-type structure with acoustically coupled parallel resonators;
FIG. 12B is a schematic plan view of a BAW component with a ladder-type structure according to FIG. 12A with parallel resonators arranged laterally adjacent to one another and acoustically coupled with one another;
FIG. 13A is a circuit diagram of a basic element of a BAW component with a ladder-type structure with acoustic coupling between a series and a parallel resonator;
FIG. 13B is a BAW component with series resonators and parallel resonators arranged over one another and with acoustic coupling between the series and the parallel resonators, which is shown in a schematic cross-sectional view on the left side of the Figure and in a Circuit diagram on the right side of the Figure;
FIG. 14A is a circuit diagram of a T-element of a BAW component with acoustic coupling between a parallel resonator and a series resonator;
FIG. 14B is a schematic cross-sectional view of a BAW component with a resonator stack with acoustic coupling between series resonators and a parallel resonator;
FIG. 15A is a circuit diagram of a π element of a BAW component with acoustic coupling between series and parallel resonators;
FIG. 15B is a BAW component with a resonator stack with acoustic coupling between series and parallel resonators which is shown in schematic cross-section on the left side of the Figure and in a circuit diagram on the right side of the Figure;
FIG. 16A is a circuit diagram of a BAW component with a ladder-type structure with acoustic coupling between series and parallel resonators;
FIG. 16B is a schematic cross-sectional view of a BAW component with a resonator stack with acoustic coupling between series and parallel, resonators arranged over one another;
FIG. 16C is a top plan view of the BAW component according to FIG. 16B ;
FIG. 17A is a circuit diagram of a BAW component suitable for feeding a balanced signal with a ladder-type structure with acoustic coupling between series and parallel resonators;
FIG. 17B is a schematic top plan view of the BAW component according to FIG. 17A ;
FIG. 18A is a circuit diagram of a BAW component suitable for feeding a balanced signal with a ladder-type structure with acoustic coupling between the series and parallel resonators; and
FIG. 18B is a schematic top plan view of the BAW component according to FIG. 18A .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Elements that are identical or have identical functions are provided in each case with identical reference numbers in all Figures.
The principles of the present invention are particularly useful when incorporated in a component shown in cross-section in FIG. 2A . The component has a resonator layer region RSB with a first electrode layer E 1 , a second electrode layer E 2 and a piezoelectric layer PS 1 arranged therebetween. The resonator layer region RSB is arranged on a carrier substrate TS. Between the resonator layer region RSB and the carrier substrate TS, an acoustic mirror AS is provided, whose structure represents an alternating sequence of layers with a layer HZ of a high acoustic impedance and layers LZ and LZ 1 with a low acoustic impedance. Such a mirror is known per se. The electrode layer E 1 is structured in a lateral plane to form sub-electrodes E 11 and E 12 . In a similar way, the electrode layer E 2 is structured in the lateral plane to form sub-electrodes E 21 and E 22 . The sub-electrodes E 11 and E 21 are arranged over one another and form together with the piezoelectric layer PS 1 lying therebetween a sub-resonator R 11 , which is connected to the first electrical gate P 1 . The sub-electrodes E 12 and E 22 arranged over one another form together with the piezoelectric layer lying therebetween a sub-resonator R 12 . which is connected to a second electrical gate P 2 . The acoustic coupling of the sub-resonators R 11 and R 12 in the lateral direction is represented schematically by an arrow.
The lateral coupled sub-resonators or rather their sub-electrodes are spaced apart, preferably by 0.5 μm to 2 μm, in order to obtain an optimum lateral coupling.
FIG. 2B shows a component according to the invention with four sub-electrodes E 11 , E 12 , E 13 and E 14 for each electrode layer. It is possibly advantageous for setting a desired impedance if these sub-electrodes are formed differently. Arrows designate the lateral acoustic coupling of the corresponding sub-resonators that lie below each of the sub-electrodes E 11 , E 12 , E 13 and E 14 .
FIG. 2C shows a different embodiment of the invention in schematic cross-section. In the multi-layer structure of a BAW component, more than just one resonator layer region is provided and, as illustrated, the component has resonator layer regions RSB, RSB 1 and RSB 2 , which are arranged one over the other.
The resonator layer region RSB is structured as shown in FIG. 2A . The resonator layer region RSB 1 includes electrode layers E 3 and E 4 and a second piezoelectric layer PS 2 arranged therebetween. The resonator layer region RSB 2 includes a piezoelectric layer PS 3 arranged between electrode layers E 5 and E 6 . The electrode layers E 3 , E 4 , E 5 and E 6 are structured in the lateral plane to form sub-electrodes E 31 , E 32 , E 41 , E 42 , E 51 , E 52 , E 61 and E 62 .
An acoustically at least partially transmissive coupling layer system KS 1 is arranged between electrode layers E 2 of the resonator layer region RSB and E 3 of the resonator layer region RSB 1 . In a similar way, a second coupling system KS 2 is arranged between electrode layer E 4 of the resonator layer region RSB 1 and E 5 of the resonator layer region RSB 2 .
The coupling layer systems KS 1 and KS 2 are used to transfer acoustic energy and can consist in each case of one layer, for example silicon oxide, or a plurality of layers, for example a layer sequence made up of SiO 2 and AIN. Through the coupling layer KS 1 , sub-resonators R 11 and R 21 arranged over one another as well as R 12 and R 22 are at least partially acoustically coupled. In a similar manner, the coupling layer system KS 2 acoustically couples in a vertical direction the sub-resonators R 21 to R 31 and R 22 to R 32 .
The coupling layer system includes acoustically partially transmissive layers which have, in each case, preferably a thickness of an uneven number of quarter wavelengths and an alternating sequence of layers with high and low acoustic impedance. The coupling degree of a coupling layer system can be set using the material characteristics, thickness and number of intermediate layers. The bandwidth of a coupling layer system and an acoustic mirror are set so that the undesired couplings or acoustic modes at frequencies below and above the passband, preferably below half the operating frequency and above twice the operating frequency, are suppressed.
In the embodiment of the invention, unlike, for example, the variant of the invention shown in FIG. 2A , there also exists, in addition to the lateral acoustic coupling of the directly adjacent sub-resonators of the resonator layer region, a vertical acoustic coupling of the sub-resonators arranged over one another within a resonator stack. Here, the sub-resonators of a resonator stack are electrically isolated from the sub-resonators of the other resonator stack. The excitation of the resonators takes place by applying an electrical signal to the sub-resonator R 11 (here arranged above) of the first resonator stack. The output signal is taken preferably at a sub-resonator R 12 of the second resonator stack that is coupled acoustically laterally with this sub-resonator.
It is provided according to the invention that sub-resonators arranged directly over one another have a common middle sub-electrode. Here, a particularly efficient acoustic coupling is obtained in the vertical direction.
In FIG. 3A , a circuit diagram shows a bridge connection, known per se, of a BAW resonator which has sub-resonators R 1 , R 2 , R 3 and R 4 . The sub-resonator R 1 is connected between the electrical terminals A 1 and B 1 . The sub-resonator R 2 is connected between the electrical terminals A 1 and B 2 . The sub-resonator R 3 is connected between the electrical terminals A 2 and B 1 . The sub-resonator R 4 is connected between the electrical terminals A 2 and B 2 .
FIG. 3B shows an implementation corresponding to the circuit diagram of FIG. 3A , which is known from U.S. Pat. No. 6,278,342 B1 of a resonator bridge connection with sub-resonators R 1 , R 2 , R 3 and R 4 arranged adjacent to one another in a schematic top view. The shaded areas are the metallizations and the electrodes formed from them. The piezoelectric layers are arranged between these shaded areas.
FIGS. 4A and 5A show, in each case, circuit diagrams of an advantageous additional development of the invention with bridge connections of sub-resonators R 1 , R 2 , R 3 and R 4 . In FIG. 5A , pairs of sub-resonators R 2 and R 4 or R 1 and R 3 have, in each case, a lateral acoustic coupling between each other. In FIGS. 4B and 5B , in each case, an exemplary implementation of bridge connections corresponding to FIGS. 4A and 5A of sub-resonators is shown in a schematic top view.
FIGS. 4A and 5A show, in each case, a BAW component containing a resonator layer region which includes, as in FIG. 2A , a first electrode layer E 1 arranged above and a second electrode layer E 2 arranged below and a piezoelectric layer PS 1 arranged therebetween, the electrode layers being structured in the lateral plane so that each electrode layer is sub-divided in at least four sub-electrodes like the sub-electrodes E 11 , E 12 , E 13 and E 14 shown in FIG. 2B . In each case, two sub-electrodes arranged over one another form together with the piezoelectric layer PS 1 lying therebetween a sub-resonator R 11 , R 12 in FIG. 2A corresponding to the sub-resonators R 1 , R 2 , R 3 , R 4 in FIGS. 4A and 5A . The sub-resonators R 1 , R 2 , R 3 , R 4 are formed in this manner are interconnected in a bridge connection. At least two of the sub-resonators R 1 , R 2 , R 3 , R 4 arranged laterally adjacent to one another are coupled acoustically through lateral acoustic mode. The acoustic coupling between the corresponding sub-resonators is shown schematically in FIGS. 4A , 5 A, 4 B and 5 B using arrows.
An embodiment of the invention showing a bridge connection by a resonator stack is shown in FIG. 6 . FIG. 6 shows a BAW component with a multi-layer structure containing at least two piezoelectric layers PS 1 and PS 2 , an upper electrode layer OE, a lower electrode layer UE and a middle electrode layer ME 1 arranged between the piezoelectric layers, with at least one of the electrode layers OE, ME 1 and UE being structured in the lateral plane so that that electrode layer is formed into at least two sub-electrodes ME 11 and ME 12 . Each of the sub-electrodes ME 11 and ME 12 forms, along with the electrode layers UE and OE arranged thereunder or thereover and the piezoelectric layer PS 1 and PS 2 lying therebetween sub-resonators R 1 , R 2 , R 3 or R 4 . Sub-resonators R 1 , R 2 , R 3 and R 4 formed in this manner form with one another a bridge connection. The sub-resonators R 1 and R 4 or, respectively, R 2 and R 3 , which are not electrically connected to one another, have preferably approximately equal or slightly different resonant frequencies. The region lying over the sub-electrode ME 12 of the upper electrode layer OE is thickened up preferably through a material layer arranged thereover made of the same or another material. The region lying under the sub-electrode ME 11 of the lower electrode layer UE is thickened up preferably through a material layer arranged thereunder made of the same or another material. With the change in the layer thickness of an electrode layer region, it becomes possible to reduce, for example, the resonant frequency of the corresponding sub-resonator R 1 or R 4 with respect to the resonant frequency of the other sub-resonator R 3 or R 4 arranged adjacent to it and containing the same piezoelectric layer PS 1 or PS 2 . The layer thicknesses of the piezoelectric layers PS 1 and PS 2 are chosen to be preferably approximately equal.
It is possible in another variation of the invention that at least eight sub-resonators form more than one bridge connection, and the bridge connections are connected in series.
FIG. 7A shows a circuit diagram of a cascade circuit with two bridge connections. A first bridge connection is formed as in FIG. 4A . Reference numbers R 1 ′, R 2 ′, R 3 ′ and R 4 ′ stand for sub-resonators of a second bridge connection with is formed similarly or identically to the first bridge connection. FIG. 7B shows sectionally a component according to the invention corresponding to this cascade circuit. Here, unlike the exemplary embodiment shown in FIG. 6 , the upper electrode layer OE and the lower electrode layer UE are structured, in each case, to form sub-electrodes OE 1 and OE 2 or UE 1 and UE 2 . The sub-electrode OE 1 forms together with the middle electrode layer ME 1 and the piezoelectric layer PS 1 lying therebetween the resonator R 1 , while a sub-resonator R 1 ′ is formed by the sub-electrode OE 2 , the middle electrode layer ME 1 and a portion of the piezoelectric layer PS 1 lying therebetween. The sub-electrode UE 1 forms together with the middle electrode layer ME 1 and the piezoelectric layer PS 2 lying therebetween the sub-resonator R 2 , while a sub-resonator R 3 ′ is formed by the sub-electrode UE 2 acting with the middle electrode ME 1 and a portion of the piezoelectric layer PS 2 lying therebetween. Here, sub-resonators R 1 and R 2 , R 1 ′ and R 3 ′ arranged over one another are coupled with one another acoustically and electrically via the middle electrode layer ME 1 .
Through a cascade circuit with a plurality of bridge connections, a particularly high selectivity can be obtained. The series connections of the bridge connections in a resonator stack take place particularly simply by means of the upper electrode layer OE and the lower electrode layer UE.
FIGS. 8A , 8 B and 8 C show, in each case, circuit diagrams of an advantageous further development of the invention. In the component, first and second signal paths are present, the first signal path being arranged between electrical gates A 1 and A 2 and the second signal path between electrical gates B 1 and B 2 . The first and second signal paths can implement, for example, a transmission path and a corresponding reception path of a filter, the transmission and reception paths being formed to transmit a signal and receive a signal of the same mobile radio system.
In general, in this variation of the invention, the first signal path or parallel to the first signal path, a first resonator, which may be SRA or PRA, is arranged. In the second signal path or parallel to the second signal path, a second resonator SRB or PRB is arranged. Here, the first and second resonators are acoustically coupled. The acoustic coupling between the corresponding resonators is indicated in FIGS. 8A , 8 B and 8 C and in subsequent Figures everywhere with arrows.
In the first signal path in FIG. 8A , a first resonator SRA, which is a series resonator, is arranged. Parallel to the second signal path, a second resonator PRB, which is a parallel resonator, is arranged. The first series resonator SRA and the second parallel resonator PRB are acoustically coupled.
It is also possible that the first resonator PRA is arranged parallel to the first signal path and the second resonator SRB in the second signal path and that they are acoustically coupled with one another.
In the exemplary embodiment shown in FIG. 8B , the first resonator SRA is arranged in the first signal path and the second resonator SRB is arranged in the second signal path and both are acoustically coupled resonators SRA and SRB being formed here as series resonators in different signal paths.
In the next exemplary embodiment shown in FIG. 8C , both the first resonator PRA is arranged parallel to the first signal path as well as the second resonator PRB parallel to the second signal path, both acoustically coupled resonators PRA and PRB being formed here as parallel resonators in different signal paths.
The first resonators SRA and PRA and the second resonators SRB and PRB can be arranged over one another in a resonator stack, and a coupling layer system is then arranged between the first and second resonators. In this case, the resonators are coupled acoustically in the vertical direction.
Another possibility consists of arranging the first resonators SRA and PRA and the second resonators SRB and PRB laterally adjacent to one another. In this case, the resonators are coupled acoustically through a lateral acoustic mode.
FIGS. 9A and 9C show, in each case, a BAW component according to the invention in a further configuration.
In general, this is a component with a multi-layer structure which contains an upper piezoelectric layer PSO, a lower piezoelectric layer PSU and at least one middle piezoelectric layer PSM arranged therebetween with a continuous upper electrode layer OE arranged above the upper piezoelectric layer PSO, a continuous lower electrode UE arranged below the lower piezoelectric layer PSU. The middle electrode layer ME 1 is arranged between the piezoelectric layer PSO and PSM, while a middle electrode layer ME 2 is arranged between the piezoelectric layer PSM and a coupling layer system KS 1 and a middle electrode layer ME 3 is arranged between the coupling layer system KS 1 and the lower piezoelectric layer PSU. At least two of the middle electrode layers ME 1 , ME 2 and ME 3 are structured in the lateral plane to form structure layers so that each structured layer has two electrically isolated sub-electrodes, such as E 11 , E 12 , E 21 , E 22 , E 31 , E 32 , as shown in FIG. 9A . The pairs of sub-electrodes, such as E 11 and E 21 or E 12 and E 22 , or the pairs of electrodes and sub-electrodes, such as E 31 and UE, E 32 and UE, E 11 and OE, or E 12 and OE which are arranged over one another form, together with the piezoelectric layer lying therebetween in each case, a sub-resonator, such as R 1 , R 2 , R 3 , R 4 , R 5 and R 6 . Sub-resonators R 1 and R 4 in FIG. 9A are arranged adjacent to one another and contain one of the middle piezoelectric layers PSM. The sub-resonators R 2 and R 3 containing the topmost electrode layer OE form, in each case, a coupling sub-resonator and the coupling sub-resonators formed in this manner are coupled, in each case, acoustically to the sub-resonator R 1 and/or R 4 lying thereunder, respectively.
The sub-resonator R 1 is used preferably to couple in an electrical signal via the first electrical gate P 1 . The sub-resonator R 4 arranged laterally adjacent to the sub-resonator R 1 is used preferably to couple out a signal via the second electrical gate P 2 . The resonators R 1 and R 4 are electrically isolated from one another and are coupled acoustically via a series connection of the coupling sub-resonators R 2 and R 3 in a vertical direction, upward, as well as via a series connection of the coupling sub-resonators R 5 and R 6 in the other vertical direction, downward, so that there are two acoustic paths that are independent of one another. The BAW component of this sort is suitable particularly for implementing a balun functionality of the BAW filter.
FIG. 9A shows schematically that the upper piezoelectric layer PSO and the middle piezoelectric layer PSM arranged directly thereunder which is used to couple the signal in and out have approximately the same layer thickness d 1 . The layer thickness d 1 corresponds essentially to a half wavelength. The layer thickness d 2 of the lower piezoelectric layer PSU or additional middle piezoelectric layers can be chosen differently from the layer thickness d 1 .
It is also possible to arrange a coupling layer system between the upper piezoelectric layer PSO and the middle piezoelectric layer PSM lying thereunder in order to control the degree of coupling between the sub-resonators R 1 /R 2 and R 3 /R 4 . Here, the thickness of the layer PSO is chosen to be less than the thickness of the layer PSM, the coupling layer system lying directly thereunder being preferably half of a wavelength. Different thicknesses of the piezoelectric layers are advantageous since, in this manner, additional pole points or rather maxima can be generated in the transfer function.
FIG. 9B shows a circuit diagram corresponding to the BAW component presented in FIG. 9A .
FIG. 9C shows a variation of the BAW component represented in FIG. 9A . The middle electrode layer ME 3 arranged directly over the lower piezoelectric layer PSU is formed continuously here, which corresponds to a parallel connection of the sub-resonators R 5 and R 6 .
FIG. 10A shows the circuit diagram of a ladder-type structure with series resonators SR, SR 1 , SR 2 , which are arranged in a signal line between a first electrical gate P 1 and a second electrical gate P 2 and which are acoustically coupled with one another. FIG. 10A also shows parallel resonators PR and PR 1 , which are connected in parallel to the signal line.
The circuit of FIG. 10A can be implemented with a design show in FIG. 10B with a resonator stack. The resonator stack has series resonators SA, SA 1 arranged outside and at least one series resonator SI arranged therebetween with middle electrode layers ME 1 and ME 2 . The series resonators SA, SI and SA 1 connected in the signal path and arranged in the stack and also interconnected outside and inside are arranged over one another and acoustically coupled with one another. The sequence of the resonator in the interconnection corresponds to the relative arrangement in the stack. At least two of the middle electrode layers ME 1 and ME 2 are interconnected in each case with a parallel resonator PR or PR 1 connected in parallel to the signal path. The series resonator SI, which is arranged inside or between the resonators SA and SA 1 in the stack, is electrically connected to the parallel resonator PR by means of a bond wire BD.
The resonators PR 1 , SA 1 and PR are arranged adjacent to one another and contain the same piezoelectric layer PS 3 .
The lateral cross-sectional area of the series resonators arranged over one another decreases from resonator to resonator upward, so that the electrode layer ME 1 arranged directly on the inside resonator SI provides a connecting surface for a bond wire connection BD.
Through the acoustic coupling of the series resonator, in particular the ripple in the passband of the bandpass filter is improved. The edge steepness of the transfer function and the rejection band suppression are also improved.
In FIG. 10C , a variant of a BAW component in the form of a T-element with series resonators SR, SR 1 coupled acoustically in the lateral and vertical direction or rather parallel resonators PR, PR 1 that are acoustically laterally coupled and arranged in series is shown in a schematic cross-section. In FIG. 10D , the corresponding circuit diagram is provided. The series resonators SR and SR 1 are formed in a resonator stack through a suitable structuring of the electrode layers so that they have, in each case, sub-resonators R 1 and R 2 or R 3 and R 4 arranged over one another. The series resonators of each stack are electrically connected to one another and are connected to the parallel resonator PR preferably through a continuous electrode layer UE arranged therebelow. The parallel resonators PR and PR 1 are formed as sub-resonators in a resonator layer region and arranged laterally adjacent to one another. In this exemplary embodiment, the parallel resonators PR and PR 1 arranged adjacent to one another, as well as the sub-resonators R 1 and R 4 and R 2 and R 3 , are coupled through a lateral acoustic mode. Moreover, the sub-resonators R 1 and R 2 and R 3 and R 4 arranged over one another are coupled acoustically to one another in a vertical direction. It is also possible for the parallel resonators PR and PR 1 to be arranged over one another in a resonator stack and coupled acoustically in the vertical direction.
FIGS. 11 and 12B present additional embodiments of the invention. These embodiments represent a BAW component with the following features: a signal path arranged between a first electrical gate P 1 and a second electrical gate P 2 , a plurality of series resonators SR, SR 1 and SR 2 and parallel resonators PR and PR 1 arranged adjacent to one another, which have, in each case, two electrodes and a piezoelectric layer arranged therebetween, at least one of the series resonators being acoustically coupled with the series resonator arranged adjacent to it, such as illustrated by the circuit diagram in FIG. 10A , or at least one of the parallel resonators being acoustically coupled with the parallel resonator arranged adjacent to it through a lateral mode, such as illustrated by the circuit diagram in FIG. 12A .
In FIG. 11 , the embodiment of the invention corresponds to the circuit diagram of FIG. 10A , with coupled series resonators SR, SR 1 and SR 2 . These resonators are arranged, unlike in FIG. 10B , adjacent to one another in series and coupled acoustically in the lateral direction.
In order to prevent the emergence of the acoustic wave excited in series resonators SR and SR 2 arranged on the outside of the lateral arrangement, one can use apparatuses in the outside edge region of these resonators to attenuate the waves. In FIG. 11 , the series resonators arranged in series are surrounded by reflectors RE and RE 1 , which serve to reflect the surface wave excited on the surface and coupled with the lateral acoustic mode.
In addition, the series resonator SR 1 is composed of two sub-resonators SR 11 and SR 12 , which are connected in series and arranged adjacent to one another.
FIG. 12A shows the circuit diagram of a ladder-type structure with acoustically coupled parallel resonators PR and PR 1 arranged in different parallel branches of the circuit.
FIG. 12B shows an embodiment of the invention corresponding to the circuit diagram of FIG. 12A with parallel resonators PR, PR 1 arranged adjacent to one another and acoustically coupled with one another in the lateral direction. The acoustic coupling between the parallel resonators PR and PR 1 is obtained particularly through a low lateral spacing between its electrodes. The lateral acoustic coupling between the series resonators SR, SR 1 and SR 2 is preferably suppressed in this exemplary embodiment.
In the design of BAW components, it can be advantageous possibly with regard to the improvement of the transmission characteristics of a component to acoustically couple a series resonator SR with a parallel resonator PR as shown by the circuit diagram in FIG. 13A , which tends to be seen as more of a disadvantage in the previously-known components and was avoided. FIG. 13B presents an exemplary implementation of a component of this type. FIG. 13B shows a BAW component with a resonator stack, with a signal path which is arranged between a first electrical gate P 1 and a second electrical gate P 2 . The resonator stack has a series resonator SR and a parallel resonator PR which are arranged over one another and are acoustically coupled with one another and which form a coupling pair. The series resonator SR is arranged in the signal path and the parallel resonator PR is connected parallel to the signal path.
The arrangement according to the invention of an electrode layer UE 11 connected to a reference potential or ground below in the resonator stack allows a simple configuration and mutual connection of individual elements of a ladder-type structure. The design takes place preferably so that the parallel resonators contain the lowest piezoelectric layer, the lowest electrode layer UE 11 in the resonator stack being connected to the reference potential and is possibly a continuous electrode layer. The series resonators are arranged preferably adjacent to one another, and they contain a common piezoelectric layer.
In the preferred variation of the invention, series resonators SR and parallel resonators PR of the coupling pair are electrically connected to one another through a common middle electrode, such as the electrode layer ME. It can be provided that the series resonator SR and the parallel resonator PR are coupled by a coupling layer system which is arranged therebetween and is acoustically at least partially transmissive.
A component according to the invention can contain additional electrically interconnected coupling pairs which are arranged in the lateral direction adjacent to one another and are formed preferably in a resonator stack.
In FIG. 14A , a T-element with a parallel resonator PR, which is acoustically coupled to two series resonators SR and SR 1 , is presented in a circuit diagram. FIG. 14B shows an exemplary implementation of a circuit of this sort in a resonator stack. The series resonators SR and SR 1 are formed as sub-resonators and are electrically and acoustically connected in the vertical direction via the middle electrode ME with the parallel resonator PR. The otherwise hard to access middle electrode layer ME serves here only as an electrical star connection of the two series resonators with a parallel resonator.
FIG. 15A shows a π element with two series resonators SR and SR 1 connected in series which are each acoustically coupled with a parallel resonator PR and PR 1 , respectively. FIG. 15B shows, on the left side, an exemplary embodiment of a circuit of this sort in a resonator stack. The series resonators SR and SR 1 and the parallel resonators PR and PR 1 are formed as sub-resonators. The resonators SR and PR as well as the resonators SR 1 and PR 1 are arranged one over the other and are acoustically coupled in the vertical direction. The electrical gates P 1 and P 2 are connected, in each case, to sub-electrodes formed from the middle electrode layer ME. A circuit diagram of this variation of the invention is shown in the right side of FIG. 15B .
FIG. 16A presents T-elements connected in series with acoustically coupled series and parallel resonators. Here, the parallel resonator PR is acoustically coupled to series resonators SR and SR 1 . A parallel resonator PR 1 is acoustically coupled to series resonators SR 2 and SR 3 . In FIG. 16B , an exemplary implementation of the circuit of this type is shown in schematic cross-section as a resonator stack. The corresponding top view can be seen in FIG. 16C . The electrode layer OE 11 arranged above is structured in the lateral plane so that sub-electrodes E 11 , E 12 and E 13 occur. The electrode layer ME arranged in the center is structured into sub-electrodes E 21 and E 22 .
FIGS. 17A and 18A present additional possible interconnections of T-elements, such as formed by the circuit diagram of FIG. 14A . These circuits are suitable for conducting a balanced electrical signal. In this case, the connection of the lower electrode layer UE 11 to a common reference potential is not necessary. Instead, an electrical connection with one another of the parallel resonators connected in parallel to different signal lines takes place in this full-area layer. Here, instead of an electrode layer, the topmost layer of the acoustic mirror with a high acoustic impedance can be used insofar as it is formed from an electrically conductive material.
Besides the excitation of an acoustic wave in series resonators SR, SR 1 and parallel resonators PR, PR 1 in the variations of the invention illustrated in FIGS. 13B , 14 B and 15 B to 18 B, an additional mode is excited in resonators or sub-resonators formed between the top electrode layer OE 11 and the bottom electrode layer UE 11 . The undesired excitation of the fundamental mode of such resonators takes place at a frequency which corresponds to about half of the operating frequency. This effect can be suppressed through a suitable selection of bandwidth of the acoustic mirrors AS. The harmonic excitation of such resonators stakes place approximately at the frequency of the resonator SR, SR 1 , PR and PR 1 . Through a suitable selection of the relative electrode layer thicknesses, it is possible to set the resonant frequencies of individual resonators under discussion so that a pole point is produced in the passband intentionally at the upper or lower stop band edge of the filter, which leads to an increase in the rejection band suppression.
An offset between resonance frequencies of the series and parallel resonators can be obtained using different relative thicknesses of the piezoelectric layers or electrode layers.
In all embodiments or variations of the invention, it is provided that the layers of the multi-layer structure can consist, in each case, of multiple layers. Different variants of the invention or its essential elements can be combined with one another in an arbitrary manner, particularly in series or parallel to one another. In particular, acoustic coupling of the resonators in a circuit can exist simultaneously in the vertical or lateral direction.
The frequency offset with resonators or sub-resonators arranged adjacent to one another can be achieved everywhere by thickening the electrodes, preferably the upper sub-electrodes.
The shown filter structures with acoustically laterally and/or vertically coupled sub-resonators can be used in combination with concentrated elements including inductances, particularly series inductances in the parallel branches, capacitances, line sections, etc. Suppression of lateral modes in undesired directions can also be achieved through corresponding configuration of the electrodes, neutralizing, for example through structuring of the piezoelectric layer or thickening of the edge regions of the electrodes. The suppression of undesired longitudinal modes can take place, for example, using roughened regions of the acoustic mirror. All of the variants of the invention are applicable, moreover, to BAW resonators and components formed with membrane technology.
Since the presentation of the invention was not possible with more than a few exemplary embodiments, it is not limited to the presented exemplary embodiments. Within the context of the invention, additional possible variations are imaginable, which make use of the teachings according to the present invention and are covered by the claims. | A component that functions with bulk acoustic waves, particularly a bandpass filter, has an increased number of degrees of design freedom in order to improve the transmission characteristics of the component. The component has BAW resonators coupled acoustically in the vertical and/or lateral direction through common electrodes, coupling layer systems and through the excitation of lateral acoustic modes. Through the acoustic coupling of the resonators, it is possible to create additional pole points in the transfer function so that in this manner, the rejection band characteristics of a bandpass filter can be improved. Through acoustic paths which are added in addition to the electrical connection, the insertion loss can be reduced. Through an acoustic coupling instead of an electrical connection, decoupling between input and output loops of a circuit can be achieved. | 7 |
This is a continuation of application Ser. No. 07/314,538, filed Feb. 23, 1989, now abandoned.
This invention relates to a novel method of manufacturing carbon fiber from a precursor comprising polyacrylonitrile polymer and, more particularly, to a novel approach in stabilizing the precursor prior to the carbonization that provides the carbon fiber.
Carbon fiber is a well known material useful in a variety of applications in view of its mechanical, chemical and electrical properties. Carbon fiber is particularly reknown for making lightweight composites comprising the fiber in inorganic or organic matrices.
The cost of carbon fiber has been decreasing significantly as compared to when it was first introduced several years ago while the properties and reliability also have been enhanced during this time. There still exists, however, long felt need for improvement in several aspects of carbon fiber manufacture. For example, the stabilization step, wherein polyacrylonitrile polymer in the form of a tow comprising a multitude of filaments is heated in air or other gaseous medium comprising oxygen prior to carbonization undesirably controls the rate at which carbon fiber is manufactured on a large scale.
Stabilization through oxidation is rate controlling because of the risk of fusing the filaments or even thermal runaway if the precursor is heated too fast or too high during the stabilization. The risk of thermal runaway is resultant of the use of certain monomers in making polyacrylonitrile polymer forming the filaments which, although permitting the oxidation reaction to commence at a lower temperature, also makes the fiber susceptible to thermal runaway. If such monomers are not used in making the polyacrylonitrile polymer precursor, then the precursor must be heated to still higher temperatures for initiation of the oxidation reaction which stabilizes the precursor and use of such higher temperatures runs even a higher risk of fusion of the filaments or thermal runaway.
Furthermore, as can be understood, reliability in manufacturing carbon fiber is currently and critically dependent upon careful manufacture of the precursor so it contains precise amounts of the monomer, e.g. acrylic acid, which enhances oxidation at lower temperatures. In addition, the oxidation reaction must be carefully controlled so the precursor is not heated too fast causing thermal runaway. Still further, the use of polyacrylonitrile homopolymer, more economical to make, has remained impractical to use as a precursor for carbon fiber.
Others have addressed pyrolysis or other heating of polyacrylonitrile precursor prior to carbonization. For example, U.S. Pat. No. 4,100,004 suggests dividing up the stabilization step so that the precursor is heated in separate temperature zones. Moreover, U.S. Pat. Nos. 3,775,520 and 3,954,950 suggest utilizing an initial brief heating step in an inert atmosphere prior to oxidizing the precursor. This initial heating step said to drive off residual solvent, is characterized by controlled shrinkage and may be undertaken in an inert atmosphere. These later patents, however, suggest limiting the initial brief heating step to prevent stabilization from occurring.
Failure of the prior art to mitigate problems associated with the rate controlling nature of the stabilization step is not because of lack of systematic study of the stabilization reaction. See, for example, "Studies on Carbonization of Polyacrylonitrile Fibre--Part 5: Changes in Structure with Pyrolysis of Polyacrylonitrile Fibre: by Miyamichi, et al., Journal of Society of Fibre Science and Technology, Japan, 22, No. 12, 538-547 (1966). Moreover, U.S. Pat. No. 2,445,042 has long ago suggested heating Polyacrylonitrile polymer in an inert medium although this patent suggests "air" is an "inert medium" and that discoloration be preferably prevented.
SUMMARY OF THE INVENTION
Now, in accordance with this invention, it has been discovered that stabilization of polyacrylonitrile polymer based precursor in making carbon fiber may be divided into separate reactions in a manner that eliminates the risk of thermal runaway otherwise existing when stabilization is made to occur in an oxygen containing environment. More particularly, the precursor is readily and safely stabilized in a form that is capable of being oxidized for subsequent carbonization. This form is achieved by heating the precursor in an atmosphere substantially free of oxygen in practice of this invention to form a thermally stabilized precursor followed by oxidation of the thermally stabilized precursor to provide a stabilized precursor that is oxidized for subsequent carbonization. Oxidation of the precursors according to this invention may be below temperatures ordinarily used for oxidation or alternatively may be at usual oxidation temperatures (e.g. between about 200° and 400° C.) or higher but at faster rates. Carbonization conditions after oxidation follow usual procedures practiced heretofore in making carbon fiber from polyacrylonitrile precursor.
BRIEF DESCRIPTION OF DRAWINGS
FIGS. 1-14 display graphically results of testing made according to the Examples.
DETAILED DESCRIPTION OF THE INVENTION
Polyacrylonitrile polymers preferred as precursors for carbon fiber manufacture in accordance with this invention are well known materials. See, for example, U.S. Pat. Nos. 4,001,382, 4,009,248, 4,397,831 and 4,452,860, which are incorporated herein by reference for a description of the manufacture of such precursors. Quite advantageously, as will become more apparent, this invention widens the type of polyacrylonitrile polymers which are able to be used in making carbon fiber. For example, polyacrylonitrile homopolymer made from monomers which consist of acrylonitrile may be readily stabilized in accordance with this invention.
The precursor is heated in an atmosphere or environment free of oxygen in a first step in accordance with this invention. During the first step, the precursor becomes "thermally stabilized" according to this invention. Preferably, the environment consists essentially of nitrogen or other inert gas, although a vacuum may be also used. The temperature to which the precursor is heated ranges preferably ranges at least about 230° C. but, advantageously, may be up to 500° C. or higher without risk of thermal runaway.
Typically, one or more tows each comprising a multitude of continuous filaments traveling as a band are heated in a furnace or oven for stabilizing the precursor in accordance with this invention. This stabilization step ranges from minutes up to about an hour or more depending on the temperature chosen and may be conducted in a series of steps, if desired.
The amount of heating the precursor is chosen to receive in accordance with this invention may be pre-determined by differential scanning calorimetry (DSC), a technique well known in the art, or other technique which measures thermal rearrangement. The difference in residual heat of reaction measured by DSC before and after heating without oxygen, is a measure of thermal rearrangement. Preferably, the residual heat of reaction by DSC in an inert atmosphere is reduced by at least about 10%, more preferably by about 20%, or even higher, e.g. about 35% or higher by heating in absence of air in accordance with this invention.
The diameter of filaments within the tow ranges between 1 and 10 microns, although the magnitude of such diameter is not critical in accordance with this invention. Moreover, each tow may comprise between 500 and 20,000 filaments per tow. The use of surface treatments on the filaments within the tow such as now practiced in the art does not distract from the benefits of this invention.
After being heated in absence of oxygen, the tows are preferably oxidized at temperatures ranging surprisingly as low as room temperature or even lower for a time to cause oxidation of the precursor tows that have been thermally stabilized. It is preferred that oxidation occurs in a gaseous medium such as air at temperatures ranging between 150° C. and 300° C. for a time sufficient to allow these thermally stabilized tows to be self supporting (i.e. retain integrity) during carbonization. Too high a temperature during oxidation is desirably avoided unless such heating is in means for carrying away thermal decomposition products of the fiber being oxidized.
In a preferred embodiment of the invention, wherein without the improvement of this invention, there is a plurality of said tows which travel together through an oven or ovens maintained at a temperature in a first range for forming said stabilized precursor that is oxidized, but wherein in accordance with the improvement of this invention, said plurality of tows travel together at a second, higher line speed than said first line speed as a band of closely spaced tows through a furnace which is substantially free of oxygen followed by travel at said higher line speed through said over or ovens, more preferably wherein said band travels through an oven or ovens maintained at a temperature below that temperature which would otherwise be optimal in providing a stabilized precursor that is oxidized.
The precursor undergoing heating in the non-oxidizing atmosphere may be stretched to a length longer than its original length before such heating, held constant in length or allowed to shrink as desired. Similarly, the precursor tows may be stretched, held constant or allowed to shrink during the oxidation reaction.
After oxidation, the thermally stabilized precursor tows that have been oxidized, as described above, are carbonized using standard techniques heretofore employed in making carbon fiber. For example, the stabilized and oxidized precursor tow is heated in an inert atmosphere or vacuum at a temperature between about 500° C. and 800° C. for tar removal followed by heating at higher temperatures, also in nitrogen or other non-oxidizing atmosphere, to yield a carbonized fiber suitable for use with or without surface treatment, as carbon fiber is now used in the art.
The following examples illustrate principles of this invention but are not intended as limiting the scope thereof. A brief description of the figures associated with these examples is set forth below.
FIGS. 1-14 graphically display results discussed in the Examples. The DSC apparatus used was a DuPont 910 DSC Module with a Model 1090 or like controller.
The X-axis in FIGS. 1 through 11C is temperature in degrees centigrade. The Y-axis is heat flow in milliwatts. FIGS. 12, 13 and 14 show load (tension) in grams per denier versus degree of reaction in percent. The degree of reaction is determined using density.
FIG. 1 sample size was 1.136 milligrams. The rate of temperature increase was 10 degrees centigrade per minute wand was in air. The FIG. 2 sample size was 1.110 milligrams and the rate of temperature increase was 10 degrees centigrade per minute in nitrogen. The sample type and rate of temperature increase are set forth below for the data in FIGS. 3-11C.
______________________________________ SampleFIG. Size Type Rate______________________________________ 3 1.332 mg AB 10 4 1.396 mg CE 10 5 1.369 mg AB 10 6 1.320 mg CE 10 7 0.243 mg AB 10 8 0.791 mg CE 10 9 1.246 mg DUP 1010 8.826 mg DUP 1011 4.624 mg DUP 1011A 1.332 mg DUP 1011B 1.327 mg DUP 1011C 3.178 mg DUP 10______________________________________
In FIGS. 1 and 2 DSC was respectively in air and nitrogen. DSC of FIGS. 3 and 4 was in nitrogen. DSC was in air for FIGS. 5, 6 (both Purge) and 7 and 8 (second heating). FIG. 9 of the DSC was in air (purge) and DSC was in nitrogen (FIG. 10) and then in air in FIG. 11. FIG. 11A was run in nitrogen; FIG. 11B run in air; and FIG. 11C is rerun in air after initial heating in nitrogen.
EXAMPLES
In the work described below "AB Precursor" and "CE Precursor" are standard carbon fiber precursors made from acrylonitrile and methacrylic acid (2 weight %) in the case of the AB precursor and acrylonitrile, methylacrylate and itaconic acid in case of the CE precursor.
Several experiments were initially run with varying degrees of nitrogen (N 2 ) pretreatment and then analyzed thermally. As seen in FIGS. 1 and 2, the amount of change in heats of decomposition (H D ) between precursor heated in air and heated in nitrogen (N 2 ) were different. These differences are typical for acrylic polymers heated in oxygen containing and oxygen free atmospheres with the low ΔH D (in N 2 ) due to thermal rearrangement reactions and the large ΔH D in air due to thermal rearrangement and oxidation reactions. Table 1 shows the results of two experiments where precursor was first pretreated in N 2 at elevated temperatures.
TABLE 1______________________________________HEATS OF DECOMPOSITION IN AIR AND N.sub.2 ΔH.sub.D Air cal/gm N.sub.2______________________________________AB Precursor (Baseline) 1121 165Pretreatment: 943 116235° C., 55 min in N.sub.2Pretreatment: 844 90.8235° C., 116 min in N.sub.2______________________________________
The change in ΔH D was 178 cal/g when heated in air after pretreatment in N 2 but only 49 cal/g when heated in N 2 after the same nitrogen pretreatment for the first sample and 277 cal/g when heated in air after pretreatment and only 74 cal/g when heated in N 2 after pretreatment for the second. Since the pretreatment heating was carried out in N 2 , it might be expected that the change in H D would be the same in both air and N 2 . However, from this data at least part of the oxidation reaction is not involved with or linked to the rearrangement reaction. If sample 1 pretreatment (235° C./55 min) had been run in air instead of N 2 , the residual H D , air would be 740 cal/g. The N 2 preheat generated only 49 cal/g, but lowered the H D , air by 178 cal/g, so it appears that 129 cal/g of reaction with oxygen was by-passed by the N 2 preheat. The N 2 preheat for 116 min at 235° C. generated 74 cal/g and lowered the H D , air by 277 cal/g so it by-passed 203 cal/g of the expected reaction with oxygen. It is evident that the chemical structure of the fiber is different when preheated in N 2 prior to air oxidation.
Samples of four different polyacrylonitrile polymers were thermally analyzed in nitrogen and air to better define the mechanisms which were occurring. As part of the analysis, ground precursor fiber was first analyzed in nitrogen, up to about 430° C. The results are shown in FIG. 3 (AB Precursor) and 4 (CE Precursor). The results were not unusual; an exponentially-increasing heat evolution peaking at about 285°-290° C., followed by a rapid heat decrease to give about 100-135 cal/g evolved heat. The resultant thermally-stabilized powder was then reweighed and reanalyzed, this time in air. Normally the air oxidation curve will follow the route shown in FIG. 5 (AB precursor) and FIG. 6 (CE Precursor). Instead, the curve shape was markedly changed. The area under the curve was significantly reduced, from about 1000-1100 cal/g to about 250 cal/g for AB Precursor and 335 cal/g for CE Precursor. In addition, the oxidation-initiation temperature was reduced about 20° C., indicating that the oxidation would be more rapid than non-prestabilized fiber (FIGS. 7 and 8). Additionally, the position of the two major thermal peaks shifted. For the AB Precursor the shift was more dramatic, with the lower peak dropping from a typical 228° C. to 212° C. The position of the higher-temperature peak increased from 326° C. to 360° C. for AB Precursor while it decreased for CE Precursor from 330° C. to 315° C.
These results suggest a major change in the oxidation reactions. There appear to be more oxidatively-active sites after the nitrogen pretreatment as evidenced by the decrease in initiation temperature. There also appears to be less overall oxidation, or possibly less dehydrogenation, as evidenced by the higher temperature which may imply more oxidative stability or may simply mean that the influence of the lower-temperature reactions is dissipated leaving only the higher-temperature part of the response.
The thermal analysis of DuPont T-42 polymer, a commercial grade polyacrylonitrile polymer fiber, in air (FIG. 9) indicates that it would be a less suitable precursor than AB Precursor due to its high initiation temperature and rapid heat evolution rate. If the precursor is first prestabilized in N 2 (FIG. 10) and then reheated in air (FIG. 11), the thermal response changes dramatically, similar to what has been seen with the other acrylic polymers. The reaction initiation temperature has decreased substantially, the single peak has split into two very distinct peaks, and the total heat of reaction is only 34 cal/gm.
PAN homopolymer, which is typically avoided at present as a carbon fiber precursor in commercial practice because of its slow reaction rate, high rate of that evolution once it begins to react, and high initiation temperature was also found to undergo dramatic changes in thermal characteristics once it was prestabilized. FIG. 11A shows the typical DSC curve for this polymer in nitrogen with a heat of decomposition of 124 cal/gm, while FIG. 11B shows the thermal curve in air. The heat of reaction in air (1103 cal/gm) is typical of other acrylic polymers, but the homopolymer is characterized by a high initiation temperature (250° C.) and rapid heat evolution rate (steep slope). When the polymer is prestabilized by running the DSC in nitrogen and then rerun in air, the changes are dramatic (FIG. 11C). The initiation temperature drops to 155° C. with the single peak splitting into two distinct peaks, the rate of heat evolution drops significantly as evidenced by a change in initial slope (note change in y-axis range between FIGS. 11B and 11C), and the overall heat of reaction has dropped to 237 cal/gm. Those results indicate the polymer may make a much more suitable carbon fiber precursor from the standpoint of ease of processability, safety, and potentially, economics.
These data also suggest that the fiber will be more easily oxidized after prestabilization. As such, a fiber which has been prestabilized and oxidized for a given time at temperature will have a higher density than a fiber which is only oxidized for the same time at temperature. A set of experiments was run to determine if this is true; the results are shown in Table 2 below.
TABLE 2______________________________________DU PONT T-42 PRESTABILIZATION AND OXIDATIONDENSITIES DensityConditions (g/cc)______________________________________235° C., 2 hr, air 1.2688235° C., 1 hr, N.sub.2 ; then 1.2904235° C., 1 hr, air235° C., 1 hr, air 1.2101235° C., 1 hr, N.sub.2______________________________________
The fiber which has been prestabilized and oxidized does exhibit a higher density than the fiber which has just been oxidized at the same temperature for the same amount of time. This is believed due to the increase in reactivity after prestabilization since prestabilization alone results in a rate of density increase which is less than that due to oxidation in air (Table 2 and FIG. 12). Looking at the density difference between the oxidized and prestabilized/oxidized fibers and assuming kinetics similar to the reaction kinetics of the AB Precursor for comparison purposes, the increase in oxidized fiber density due to prestabilization corresponds to a time savings of 40 minutes at 235° C. That is, in order to reach the same oxidized density as the prestabilized/oxidized fiber, the Precursor fiber would have to be oxidized for 160 minutes at 235° C. instead of stabilized/oxidized for a total of 120 minutes at 235° C.
Another way to monitor the reaction characteristics of an acrylic based precursor is to follow the tension which is generated as the fiber rearranges and oxidizes at elevated temperatures. Tension vs time data were generated for AB and DuPont precursors and prestabilized fibers to further clarify changes in oxidation reaction characteristics which are caused by prestabilization in an inert atmosphere.
FIG. 13 shows load/time data for AB precursor in air at 235° C., N 2 at 235° C., and for AB prestabilized for varying amounts of time and then run in air at 235° C. Comparing the samples run in air and N 2 (no stabilization), both samples show the characteristic drop in tension initially followed by a tension increase as the fiber begins to react. The tension increase due to the shrinkage of the sample run in N 2 is significantly less than in air, the difference presumably being due to the added shrinkage of the oxidation reactions occurring in air.
The prestabilized fibers show a sudden increase in tension when run in air possibly indicating an initial increase in the degree of reactivity. The load build up quickly levels out for the 60 minute prestabilized fiber, followed by 30 minute, and 5 minute which has a final load after 60 minutes, similar to AB Precursor. These lower oxidation loads could be due to a lower overall oxidation reactivity for the prestabilized fibers which would agree with DTA results showing lower than expected residual heats of reaction in air after prestabilization.
The results for the DuPont T-42 type fiber are shown in FIG. 14. This fiber is characteristically slower to react than AB as evidenced by the slow load buildup for the AB Precursor. After prestabilization, the shrinkage characteristics of the fiber are greatly altered. The tension increase with time, while not as great as for AB Precursor, is similar in shape, indicating the fiber may oxidize more readily after prestabilization. As with the prestabilized AB Precursor samples, the T-42 type fibers show a rapid initial increase in tension (the greater the degree of prestabilization, the greater the rate of tension buildup). After 60 minutes, the more highly prestabilized fiber has a lower load buildup than the other prestabilized fiber (similar to AB results) but both samples are significantly higher than the baseline indicating the prestabilization (even after as little as five minutes) results in an increase in oxidation reaction rate, but may reduce the number of sites available for reaction. These results indicate that prestabilization can be used to make certain precursor fibers more reactive while also increasing the safety of the process by reducing the oxidation exotherm.
Another interesting finding from these experiments is that prestabilization changes fiber reactively sufficiently to cause a subsequent reaction in air at room temperature.
A set of AB fibers were stabilized in N 2 at 250° C. for times ranging from 5 minutes to 6 hours. In each case, the sample was then divided in half, with half placed in an inert atmosphere and the other half stored in air, both at room temperature. In all cases, the sample in air continued to change color and slowly darken while the sample in N 2 remained golden brown. It was found that this reaction could be suspended by placing the partially darkened sample in N 2 and then reinitiated by exposing again to air. The fibers exposed to air after prestabilization were able to oxidize at room temperature. If oxidation type reactions were indeed occurring, it would be expected that the residual heat of reaction would decrease with increasing time of exposure to air at room temperature. A series of experiments was performed to determine if this was indeed the case. In one set of experiments, a length of AB Precursor was stabilized in N 2 for 2 hours at 250° C.; the fiber was divided in half with half exposed to room-temperature air for 3 hours and the other half exposed to air for 24 hours. The samples were then restored in N 2 and submitted for thermal analysis. In all cases, the thermal lab was careful to run the samples as quickly as possible after the N 2 seal was broken. In the second experiment, a sample of AB Precursor was stabilized for 16 hours at 250° C. in N 2 and then divided with parts exposed for 0 hours, 1 hour, 3 hours, and 24 hours in air. Samples were then restored in N 2 and thermally analyzed The results are shown in Table 3 below:
TABLE 3______________________________________CHANGE IN ΔH.sub.air OF STABILIZED FIBERS AFTERVARYING AMOUNTS OF EXPOSURE TIME IN AIRStabilization Conditions Air Exposure Timein N.sub.2 at Room Temperature (hr) ΔH.sub.air______________________________________ 2 hours at 250° C. 3 684 2 hours at 250° C. 24 62416 hours at 250° C. 0 67816 hours at 250° C. 1 65216 hours at 250° C. 3 60516 hours at 250° C. 24 548______________________________________
For both sets of these experiments, the heat of reaction decreased with time of exposure in air, indicating a reaction occurring at room temperature which is responsible for the color change we had noted. A stabilized fiber was also run to determine if free radicals are present, which might be initiating the reaction at room temperature in air. The results indicated the presence of some free radical activity, which is as yet unidentified. | PAN-based precursors are stabilized prior to carbonization in separate non-oxidizing and oxidizing environments according to process of the invention. Advantages of process include safer, more rapid stabilization and increase in the types of polymers which may be effectively stabilized. | 3 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Application No. 60/835,566 filed Aug. 4, 2006 and the entirety of that application is incorporated herein by reference.
TECHNICAL FIELD
[0002] This application relates to medical devices for use in surgical applications. More specifically, this application relates to ports for use in accessing an area of a body during and/or after a surgical procedure.
BACKGROUND
[0003] In minimally invasive surgical procedures, such as laparoscopic procedures, one or more small incisions are made in a body to allow access for the necessary surgical tools. If there is a need to re-enter the body after a surgical procedure, a mechanism for doing so must be put in place. For targeted or prophylactic chemotherapy, post-operative applications of a substance can be made by re-instituting an environment in the patient in which subsequent applications of the substance may be made. This may be accomplished by leaving a port device in the patient after the surgical procedure, or by surgically placing a port in the patient in preparation of a non-surgical treatment regimen.
[0004] The port may be a device capable of providing a sanitary access point to a body, where the device is a resealable mechanism that attaches to the exterior of the skin and the interior wall of the skin. The port permits a device for applying a substance to the body to be reconnected to the patient at a later time to apply the substance or other treatment. One example of this type of port is an enteral feeding tube port.
[0005] The design of re-entry ports typically focuses on semi-rigid tubes, such as feeding ports which are meant to transverse from out side the body into an organ such as the stomach. These devices often have a bulb or protrusion at the insertion end to maintain the location of the tube in the organ being accessed, and consist of a rigid or semi-rigid tube or lumen. Catheters, such as urethral catheters for access into the bladder tend to be flexible catheters, usually with a balloon or some type of protrusion that is used to anchor the catheter into the organ to prevent its movement back through the body channel. Intravenous ports, ports or needles that are inserted into a vein, are generally taped or perhaps sutured in place to prevent the accidental removal of the device. Other devices such as flat tubes with holes, sometimes under suction have been used as drains for wounds or to prevent fluid build up in the chest cavity.
SUMMARY
[0006] An improved port is described below that can remain in place, for example between physical structures such as the abdominal wall and the organs below, or in the plural cavity between the ribs and the lungs, or in any other physical location where the separation of bodily spaces may be required on a recurring basis.
[0007] According to a one aspect, an in-dwelling port is described having an external portion or flange configured for placement outside of an incision and defining a proximal port opening. A collapsible insertion portion having a distal port opening is attached to the external portion and positioned in a substantially coaxial relationship to the proximal port opening. The collapsible insertion portion is repeatably adjustable between an elongated position, where the collapsible insertion portion defines an elongated length and an elongated width, and a collapsed position, where the collapsible portion defines a collapsed length and a collapsed width. The elongated length is greater than the collapsed length and the elongated width is less than the collapsed width to allow for easy insertion, firmer placement in a collapsed position, and a less intrusive and disruptive way of leaving a port in a body when the port is not in use.
[0008] Other features and advantages of the invention will become apparent upon review of the following drawings, detailed description and claims
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a perspective view of an in-dwelling port in an elongated position.
[0010] FIG. 2 is a top plan view of the in-dwelling port of FIG. 1 .
[0011] FIG. 3 is a cross-sectional side view of the port of FIG. 1 .
[0012] FIG. 4 is a cross-sectional side view of the port of FIG. 1 in a collapsed position.
[0013] FIG. 5 . is a side view of a stylus suitable for use in inserting the port of FIG. 1 into an incision.
[0014] FIG. 6 is a top plan view of an alternative embodiment of the in-dwelling port of FIG. 1 .
[0015] FIG. 7 is a cross-sectional side view of the port of FIG. 6 in an elongated position.
[0016] FIG. 8 is a top plan view of a second alternative embodiment of the in-dwelling port of FIG. 1 .
[0017] FIG. 9 is a cross-sectional side view of the port of FIG. 8 in an elongated position.
[0018] FIG. 10 is a top plan view of a third alternative embodiment of the in-dwelling port of FIG. 1 .
[0019] FIG. 11 is a cross-sectional side view of the port of FIG. 10 in an elongated position.
[0020] FIG. 12 is a perspective view of the port of FIG. 11 .
[0021] FIG. 13 is a top plan view of a fourth alternative embodiment of the in-dwelling port of FIG. 1 .
[0022] FIG. 14 is a cross-sectional side view of the port of FIG. 13 in an elongated position.
[0023] FIG. 15 is a cross-sectional side view of a fifth alternative embodiment of the port of FIG. 1 in an elongated position.
[0024] FIG. 16 is a cross-sectional side view of the port of FIG. 15 in a collapsed position.
DETAILED DESCRIPTION
[0025] FIGS. 1-4 illustrate one version of an in-dwelling port 10 where separation of body spaces may be required on a recurring basis. This in-dwelling port 10 may be used to reinflate the space between the abdominal wall and the organs below (peritoneal cavity). The port 10 includes an outer flange 12 and a collapsible insertion portion 14 . The outer flange 12 may have a greater diameter than that of the collapsible insertion portion 14 to stabilize the port in the patient and prevent over-insertion into an incision. A proximal port opening 16 is defined by the flange 12 to allow one or more lumens or medical devices access into the collapsible insertion portion 14 . A distal port opening 18 is positioned at the end of the collapsible insertion portion 14 and permits access to the body cavity.
[0026] A replaceable plug 20 is removably insertable into the proximal port opening to prevent an infection or other foreign substances to enter the body when the in-dwelling port 10 is not in use. The plug 20 may be attached to the outer flange 12 by a tether 22 . The tether may be formed from the same piece of material as the outer flange, or it may be a separate material attached to the outer flange 14 . The plug may be a compression-style plug that is elastic enough to fill the proximal port opening 16 when pressed in place. Alternatively, the plug 20 may be a discrete component unattached by a tether. Any of a number of other fastening means, such as threaded ends, collapsible detents or other mechanisms may also be used to connect the plug and the proximal port opening.
[0027] The outer flange may include recessed regions 24 on one or more sides. The recessed regions may be sized to provide an anchor for sutures, adhesives or other devices for holding the in-dwelling port in place on the body. The outer flange may also be held in place by having an optional adhesive surface to keep it against the skin. The adhesive surface may be islands of adhesive positioned about the underside of the flange. Alternatively, to provide a more complete seal and to help prevent deterioration of the tissue through which the in-dwelling port is inserted, a continuous ring of adhesive or adhesive material may be positioned on the underside of the flange to prevent tearing and strengthen the integrity of the tissue surface. Thus, the in-dwelling port 10 may be affixed in a number of ways, individually or collectively, by suturing the recessed regions of the flange, adhering the underside of the flange to the outer tissue surface, and even covering the flange with an adhesive bandage (regular and medicated) to help keep it in place and to further help resist infection.
[0028] The collapsible insertion portion 14 of the in-dwelling port 10 may be fabricated in any manner that permits it to collapse when not in use, for example in the form of a bellows or accordion-like structure. Once past the abdominal wall or other body structure, it can gently collapse back to an almost flat shape. The flat shape may assist in reducing irritation and trauma, as well as provide very little restriction to normal body motion and limited visibility of its presence. A feature of the bellows structure of the collapsible insertion portion is that it will present a reduced diameter when elongated and may more easily go through a relatively small incision or wound site, or even a natural body passage way. Once in place, the structure will allow the collapsible insertion portion to collapse into a larger diameter so as not to work itself out of the incision, wound, or body passage. Referring to FIG. 4 , the collapsed state of the in-dwelling port expands the bellows portion to hold, for example, the abdomen wall between the flange 12 and the collapsible insertion portion 14 for a secure and low-profile point of re-entry.
[0029] Referring to FIG. 5 , a stylus 26 is designed to fit in the collapsible insertion portion 14 via the proximal port opening 16 and extend the in-dwelling port 10 to its smallest diameter for insertion into an incision. If, for example, the in-dwelling port was intended for insertion into an abdomen wall, the stylus would first be inserted into the proximal port, extending the collapsible insertion portion and thus reducing its diameter. The distal port opening 18 may be provided with a smaller diameter than the proximal port opening 16 so that the stylus 26 remains in the collapsible insertion portion during insertion. A physician may then push the in-dwelling port into position from outside the abdomen wall and into the peritoneum, for example via a trocar wound (not shown).
[0030] Once inserted, and optionally secured at the flange to the abdomen, the stylus 26 would typically be removed and one or more lumens may be introduced and later reintroduced, through the in-dwelling port. The in-dwelling port 10 may allow for the insertion of medical devices after placement by maintaining one or more access lumens to pass a medical device through it such as a catheter, or a small needle or trocar, an optical endoscope, an operative instrument or any number of surgical, diagnostic, or palliative devices.
[0031] When all lumens in the port 10 are removed and the port is not in use, the collapsible insertion portion will collapse down and allow the abdomen wall to collapse to a more relaxed position that may be substantially close to its pre-insertion shape. The plug 20 may then be inserted to provide a barrier to contaminants. Having a way to allow the separation (or re-separation) of the abdominal wall or cavity from the organs below for purposes of examination, application of medicines, or even operative tasks is desirable and is usually accomplished by insufflation of the peritoneal space. Because the port is intended for access to the bodily space for the purpose of re-expanding the separation of one layer or body structure from another the port also permits the body structure to return to its substantially normal (collapsed) position.
[0032] An alternative embodiment of the in-dwelling port 30 is shown in FIGS. 6-7 . In this arrangement, a re-sealable membrane 32 is positioned across the proximal port opening 34 . A needle or other sharp-ended introducing device may be used to pierce the membrane 32 or surface and introduce a lumen or instrument through the membrane and subsequently into the body via the distal port opening 36 . The membrane would reseal itself after removal. This pierceable membrane or cover may be manufactured from any of a number of materials, for example polysoprene, isoprene or silicone. In an alternative embodiment, the in-dwelling port may have a second proximal port opening that could be connected to a filter in order to release pressure from an expanded space, for example the peritoneum during a laparoscopic procedure, without permitting organisms to be released into the air.
[0033] In an alternative embodiment shown in FIGS. 8-9 , the in-dwelling port 40 may have a tear-away seam 44 disposed along the entire length of the port. The seam 44 may traverse the flange 42 and the collapsible insertion portion 45 to form a continuous line of perforations from the proximal port opening 46 to the distal port opening 48 . In one embodiment, the seam 44 may be a line of perforations extending longitudinally down the device from proximal 46 to distal 28 port opening, multiple parallel lines of perforations to allow for tearing the indwelling port from one or more sides of the flange 42 , or any desired pattern of perforations to allow segmented destruction and removal of the indwelling port. In alternative embodiments, the lines of perforations may be other types of weakened seams defining a continuous line of weakened or reduced thickness material that permit for a substantially clean tear when a user desires to remove the in-dwelling port.
[0034] One advantage of an in-dwelling port as shown in FIGS. 8-9 with a tear-away seam is that a new in-dwelling port may be inserted into an old indwelling port already positioned in a body and the old port could be removed by splitting and pulling out the old port. Alternatively, the old port could pulled into a sleeve device and removed, the sleeve serving to keep the space open to place a new port in place of the old port, or even a tool or a finger could be pushed along side the old port while a new port is positioned next to the tool or finger, and inserted.
[0035] The in-dwelling ports in FIGS. 1-9 are shown with one lumen through the center. In other implementations, two or more lumens may be fabricated so that more than instrument could be inserted into it, or one lumen could be attached to a pressure source such as an insufflator and the other to a suction source, or a commercially available pressure relief device (such as manufactured by Smart products), or a mini-endoscope may be inserted into one lumen an and instrument or catheter or some other operative device may be inserted into another. The device is not limited to a single useful lumen, and multiple lumens could be utilized with many other medical devices seeking entry into the body space. Other uses for the lumen(s) may include applications requiring the insertion of a fluid catheter, the use of an aerosolization or nebulizing device for the purpose of coating or treating organ cavity.
[0036] As shown in FIGS. 10-12 , an in-dwelling port 50 may be constructed with two proximal openings 52 that each lead to a respective half of the interior of a single collapsible insertion portion 62 . Each proximal opening 52 may have its own removable plug 54 attached to the flange 64 by respective tethers 56 . A collapsible partition 60 extending through the interior of the area enclosed by the collapsible insertion portion 62 defines two separate access paths 66 terminating at respective distal openings 58 . Although the access paths 66 are shown as equal in size in FIGS. 10-12 , access paths of unequal size or more than two paths in the single collapsible portion 62 are contemplated as well.
[0037] FIGS. 13 and 14 illustrate another version of an in-dwelling port 70 for allowing access for multiple devices such as noted above. In the version of FIGS. 13-14 , two completely separate collapsible insertion portions 72 are formed in a single flange member 74 . Each collapsible portion has its own proximal and distal opening 76 , 78 , where the proximal openings 76 may have a greater radius than the distal openings 78 or may be covered with a membrane suitable for piercing by a needle or other sharp instrument. Additionally, one or both collapsible portions may be partitioned internally as shown in FIGS. 10-12 to provide separate access for even more devices or instruments into a body cavity.
[0038] Although the example of in-dwelling ports described above include collapsible insertion portions, shown as bellows, that are expandable into a body cavity, there may be a need to insure that the collapsible insertion portion or bellows of the device stays up to the distal surface (i.e. the interior surface) of the tissue or organ into which the device is inserted. FIGS. 15-16 illustrate an implementation of an in-dwelling port 80 that allows for the collapsible insertion portion 82 to remain secure, and prevent it from “relaxing” or loosening and becoming partially extended in the bodily cavity. This is accomplished by having one or more threads or tethers 84 attached to the distal portion of the insertion portion, which can be used to draw-up or retract the collapsible insertion portion 82 , either through holes 86 in the top flange 88 , or along the outside of the collapsible insertion portion 82 and the outside(s) of the top flange to be secured by some means such as tying, suturing, taping or any other method of securing the tether(s) 84 in such a way as to keep the collapsible insertion portion 82 collapsed, or loosening them to allow the collapsible insertion portion 82 to be expanded. The tethers 84 can be constructed of the same material as the in-dwelling port 80 , from thread, or from any other flexible thin material. It could be accomplished with one or more such tethers 84 . The tethers 84 can be attached to the collapsible insertion portion 82 in the molding process, by heat sealing (melting), tying, gluing, or any other method of attaching the tethers to the collapsible insertion portion of the device.
[0039] In yet additional alternative embodiments, where additional rigidity of the collapsible insertion portion may be desired, a stylus such as shown in FIG. 5 may include a central bore through which instruments or lumens may be inserted. Such a modified stylus may remain in the indwelling port during a procedure and removed to allow the in-dwelling port to collapse when not in use
[0040] Any of the in-dwelling port versions described above may be coated or impregnated with antibacterial and or antimicrobial medications to prevent infection from occurring during its time in place. Such a coating for example could consist of, but is not limited to, Rifamacin, Rifampin, Minocycline, silver sulfadiazine, or Bardex R IC.
[0041] The in-dwelling port may be constructed of a resilient material that has the ability to reform its shape or accept a “retracted” shape after it is in place. Suitable materials include, but are not limited to, silicone, rubber, latex, nylon, and fabric like materials. Although any number of in-dwelling port sizes and dimensions are contemplated, and may vary depending on intended use, the example shown in FIG. 2 may have a flange major axis length A of 1.75 inches, a flange minor axis length B of 0.875 inches, and a tether length C of 0.875 inches. The proximal port opening diameter may be 0.196 inches and the distal port opening may be 0.112 inches. Accordingly, the stylus used to insert this specific version of the in-dwelling port would need to have a minimum diameter of greater than 0.112 inches and a maximum diameter of less than 0.196 inches. Referring again to FIGS. 3 and 4 , the collapsible insertion portion in this example may have a collapsed depth G of 0.375 inches and a maximum extended depth F of 5.0 inches for a greater than 5 to 1 ratio. The extended diameter H of the collapsible insertion portion is preferably less than the collapsed diameter I, however the ratio may vary depending on, for example, the number and length of the folds that form the bellows or accordion-like structure of the collapsible insertion portion.
[0042] It is therefore intended that the foregoing detailed description be regarded as illustrative rather than limiting, and that it be understood that it is the following claims, including all equivalents, that are intended to define the spirit and scope of this invention. | An in-dwelling port for providing repeated entry to a body during and/or after an operation is described. The port may include an external portion secured to a body outside an incision and a collapsible insertion portion that is inserted through the incision. The collapsible portion collapses when no instrument or lumen is present to permits the body to return to substantially a normal profile around the incision. | 0 |
FIELD OF THE INVENTION
[0001] The present invention relates to a radar level gauge system for determining the filling level of a filling material in a tank, comprising an antenna device for emitting measuring signals towards the surface of the filling material; a receiver device for receiving echo signals from the tank; and processing circuitry for determining the filling level of the tank based on said echo signal, wherein said processing circuitry is adapted to amplify the received echo signals in dependence of the distance from which the echo signals originates, in such a way that an echo signal from a lower filling level is more amplified than an echo signal from a higher filling level. Further, the invention also relates to a corresponding processing circuitry, and a method for determining the filling level of a filling material in a tank.
BACKGROUND OF THE INVENTION
[0002] Radar level gauges are in wide use for making non-contact measurements of the level of products such as process fluids, granular compounds and other materials. These devices utilize antennas to transmit electromagnetic waves toward the material being monitored and to receive electromagnetic echoes which are reflected at the surface of the material being monitored. However, in a practical situation more than one radar echo usually can be seen and the dynamic range for the variation of all possible echoes is quite large.
[0003] However, a problem experienced in this type of level gauges is that the signal strength from a surface echo reduces as a function of measured distance. Typically, the signal strength reduces by 50% if the distance is doubled. As a consequence, the dynamic range in the receiver part is not optimally used. One method known in the art to compensate for this loss of signal strength is to amplify the received signal with a magnitude which is increased as a function of distance, so called IF-gain. Further, many radar level gauge systems have to work under low current and voltages and should preferably use low cost components. Thus, many of the classical methods for increased dynamic range may not be employable.
[0004] In order to solve the above-related problem, it has been proposed to increase the signal strength of the received signals in dependence of the distance from which the echoes originates. For example, U.S. Pat. No. 6,031,421 discloses a pulsed system for radar level gauging using sensitivity time control (STC), where the amplification in the receiver is controlled to provide a exponential gain with increased distance. U.S. Pat. No. 6,107,957 discloses a FMWC (frequency modulated continuous wave) radar level gauge using a similar amplification gain-control in order to provide an amplification inversely proportional to the distance from which the echoes originate.
[0005] However, a problem with these known systems is that they are relatively insensitive and static, and unable to adapt to the specific conditions related to the tank in which they are to be used, Specifically, the known systems are conventionally dimensioned for a maximal measuring distance, e.g. 30 meters. However, in practical use the tanks are of varying height, whereby non-optimal amplification is provided.
[0006] Still further, most known systems have problems related to the noise level, due to the increased noise level generated by the amplification. This is particularly disadvantageous in measuring systems subjected to high noise levels.
[0007] It is therefore a need for a more effective amplification control for use in level gauging.
SUMMARY OF THE INVENTION
[0008] It is therefore an object of the present invention to provide a radar level gauge system, a processing circuitry for use in such a radar level gauge system and a method of determining the filling level of a filling material, which at least partly alleviate the above-discussed problems of the prior art.
[0009] This object is achieved with a radar level gauge system, a processing circuitry and a method according to the appended claims.
[0010] According to a first aspect of the invention, there is provided a radar level gauge system for determining the filling level of a filling material in a tank having a tank height, wherein the filling level is less or equal to said tank height, comprising: a transmitter for transmitting measuring signals towards the surface of the filling material; a receiver for receiving echo signals from the tank.; and processing circuitry for determining the filling level of the tank based on said echo signal, wherein said processing circuitry is adapted to amplify the received echo signals according to an amplification scheme in dependence of the distance from which the echo signals originates, in such a way that an echo signal from a lower filling level is more amplified than an echo signal from a higher filling level. The amplification scheme of the processing circuitry is further adjustable, and the processing circuitry comprises direct or indirect information on the tank height, and is adapted to adjust said amplification scheme in order to optimize the amplification of the echo signal based on the height of the tank.
[0011] With this radar level gauge system, an automatic sensitivity control is provided. Thus, the per se known functionality of amplifying the received echo signals could now be used in a much more efficient and reliable manner, since the amplification is optimized for the actual working conditions at hand, and for the actual tank in which the system is installed. The amplification could then in a more optimized way than is heretofore known, be used, e.g. by voltage control, to provide higher amplification for echoes from larger distances, Thereby, the sensitivity of the system, and consequently also the accuracy of the measurements, is maximized by adjusting the gain based on configured tank height. The amplification increase could be fixed or be controlled based on the strength of the echoes present. Theoretically, an increase of up to 12 dB is obtainable, which would render a four times as long measuring distance possible, or a doubling of the measuring distance with half as large an antenna. This has also been confirmed in practice.
[0012] By using the present invention, echoes from a far distance have the same possibility to be recognized as nearby echoes, i.e. the amplification provides the same echo signal strength regardless of the distance, and the response could be optimized for the tank height where the system is actually used. Hereby, the dynamic range of the amplification means is more effectively used, compared to known systems where the amplification is normally dimensioned for a maximal measuring distance, e.g. 30 meters, which provides a non-optimal use of the dynamic range of the amplifier when used in tanks of other heights. Since the dynamic range of the amplification means is normally limited, it is of great importance to make as effective use of said range as possible over the measuring distance in actual use. The present invention is particularly advantageous for large measuring distances.
[0013] The adjustment of the amplification scheme in order to optimize the amplification of the echo signal based on the height of the tank should be understood as an improvement of the amplification scheme compared to a non-adjusted scheme, and preferably an improvement to the highest practically feasible level. However, the highest feasible level may possibly not be the same as the highest theoretically feasible level, but may incorporate safety margins etc.
[0014] The radar level gauge system could be a continuous system, such as a FMWC system, in which the antenna device is adapted to emit continuous signals, and wherein the processing circuitry is adapted to determine the filling level based on a phase difference between the received echo signal and a reference signal. In an FMWC system, the emission is normally continuous, but with a frequency sweep. A filter arrangement, as is e.g. disclosed in U.S. Pat. No. 6,107,957, could be used for providing a greater amplification for higher frequencies compared to lower frequencies. In FMWC systems the adjustability to optimize the amplification of the echo signal based on the height of the tank could be implemented by using different, replaceable filters, or filters with controllable filter output, for processing of the signals before amplification.
[0015] However, the invention could equally well be used in a pulsed system for level gauging, e.g. a STC system, in which the antenna device is adapted to emit pulsed signals, and wherein the processing circuitry is adapted to determine the filling level based on the time between the emission of a pulsed signal and the reception of the echo of said signal. In fact, the invention is particularly usefull in this type of systems, since the above-discussed problems have previously been particularly difficult to handle in this type of system. In such a pulsed system the amplification in the receiver could be controlled to provide a exponential gain with increased distance based on the tine it takes for the echo to come back for an emitted pulse, as is disclosed e.g in U.S. Pat. No. 6,031,421. In pulsed systems, a control software could be used that provides a controllable voltage ramp for the amplification, as is discussed more thoroughly in the following.
[0016] Accordingly, the present invention could be used in essentially any type of freely emitting level gauge system.
[0017] Preferably, the processing circuitry is arranged to amplify the echo signal before any other significant processing or manipulation of the signal. Thus, the amplifier is situated relatively close to the microwave modulation (NW) module. Hereby, the noise level could be significantly reduced.
[0018] The amplification scheme of the processing circuitry is preferably adjustable to optimize the amplification of the echo signal based on the height of the tank by means of software control, based on an input tank height value. The software could e.g. be an embedded control software, executed on an conventional signal processor as is per se known in the art By using such software control, the adjustability for different tank heights etc becomes relatively simple and cost effective, making the process of installing the radar level gauge system, and adapting the system for the working conditions at hand, relatively simple.
[0019] Alternatively, the amplification scheme of the processing circuitry could be adjustable to optimize the amplification of the echo signal based on the height of the tank by means of a hardware control unit, said hardware control unit being chosen based on an estimated tank height.
[0020] The processing circuitry preferably comprises a controllable amplification means for amplification of a received echo signal according to the amplification scheme, wherein said amplification scheme comprises an amplification ramp for amplification in dependence of the distance from which the echo signals originates, and further the processing circuitry comprises a control unit for optimizing the amplification ramp based on an estimation of the height of the tank. The ramp is preferably voltage controlled as a function of the measuring distance. The range of the ramp is controlled, preferably by a controlling software, so that it corresponds to the tank height The control unit is preferably adapted to optimize the amplification ramp so that essentially the whole dynamic range of the controllable amplification means is useable for received echo signals originating from a distance range corresponding to the estimated height of the tank.
[0021] The amplification scheme of the processing circuitry is preferably adapted to control the amplification in order to provide the maximum amplification for echo signals originating from a level corresponding to the tank bottom at the actual tank. Hereby, the system could be controlled to use the full dynamic range of the amplification means in each and every tank where the system is used, regardless of e.g. varying tank heights.
[0022] Further, the processing circuitry is preferably adapted to estimate information on the tank height automatically, based on at least one previously determined filling level. Hereby, the system adapts itself automatically to new conditions, whereby the installation process becomes easier and less costly. For example, a first filling level measurement could be based on a standard value, and thereafter, better estimates of the filling level could be acquired during use, based on subsequent filling level determinations. The tank height could normally be estimated to be the lowest estimated filling level, but possibly with some adjustments related to the number of filling level determinations that have been made since installation of the system or the latest reset of the system, etc.
[0023] According to a second aspect of the invention, there is provided a processing circuitry for use in a radar level gauge system for determining the filling level of a filling material in a tank having a tank height, wherein the filling level is less or equal to said tank height, comprising: controllable amplification means for amplification of a received echo signal according to an amplification ramp in dependence of the distance from which the echo signals originates; and a control unit for optimizing the amplification ramp based on an estimated tank height of a tank in which the processing circuitry is to be used.
[0024] This processing circuitry could be used in the previously discussed radar level gauge system, and provides the same or similar advantages.
[0025] According to a third aspect of the invention, there is provided a method of determining the filling level of a filling material in a tank having a tank height, wherein the filling level is less or equal to said tank height, comprising:
[0026] transmitting measuring signals towards the surface of the filling material;
[0027] receiving echo signals from the tank;
[0028] providing an amplification scheme for amplification of the received echo signals in dependence of the distance from which the echo signals originates, in such a way that an echo signal from a lower filling level is more amplified than an echo signal from a higher filling level;
[0029] providing direct or indirect information on the tank height;
[0030] optimizing said amplification scheme based on said height of the tank;
[0031] using said optimized amplification scheme for amplification of the received echo signals; and
[0032] calculating the filling level of the tank based on said received echo signals.
[0033] This method could be used for operating the previously discussed radar level gauge system, and provides the same or similar advantages.
[0034] These and other aspects of the invention will be apparent from and elicited with reference to the embodiments described hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0035] For exemplifying purposes, the invention will be described in closer detail in the following with reference to embodiments thereof illustrated in the attached drawings, wherein:
[0036] FIG. 1 is a schematic cross-sectional side view of a container, in which an antenna device according to the embodiment is arranged;
[0037] FIG. 2 is a schematic block diagram illustrating a radar level gauging system according to an embodiment according to the invention;
[0038] FIG. 3 is a schematic block diagram illustrating a radar level gauging system according to a second embodiment according to the invention; and
[0039] FIG. 4 is a schematic diagram illustrating the amplification gain as a function of time (corresponding to distance) according to an embodiment of the invention
DESCRIPTION OF PREFERRED EMBODIMENTS
[0040] FIG. 1 shows schematically a tank 1 provided with a radar level gauge system 2 . In brief, the system in FIG. 1 comprises an electronic unit 3 for transmitting and receiving radar signals and processing the received signals in order to determine the level in the tank, an antenna 4 arranged inside the tank for transmitting and receiving radar waves into the tank, and a radar wave guide assembly 5 for guiding signals between the electronic unit 3 and the antenna 4 . In order to maintain temperature and pressure in the tank, and to protect the outside environment from the tank contents, a wave guide sealing 6 is arranged close to where the wave guide 5 passes through the tank wall 7 to provide sealing of the tank 1 . The same antenna could preferably be used both as a transmitter for emitting the output radiation and as a receiver for receiving the reflected echo signal.
[0041] In use, the radar level gauge 2 transmits radar energy along the waveguide, 5 through the tank roof port and receives reflected energy from the liquid surface 8 to provide an indication of the level of the liquid within the tank. The radar level gauge 2 could be coupled to a remote location (for example a control room) via a signal wire or the like.
[0042] The system may use pulsed or continuously emitted radiation. For systems using pulsed radiation the transit time for the pulsed signals before returning as echo signals are used for measuring the level in the container or tank. Such a pulsed system is e.g. disclosed in U.S. Pat. No. 5,822,275, hereby incorporated by reference. A transmission phase and a receiving phase form together a measurement cycle.
[0043] A processing circuitry 20 to be used in a radar level gauge system as discussed generally above is schematically illustrated in FIGS. 2 and 3 .
[0044] In the embodiment shown in FIG. 2 , circuitry 20 includes a signal processor 21 , a timing control system 22 , a Tx pulse generator 23 and a Rx pulse generator 24 . The signal processor 21 controls the timing control system, which in turns controls the Tx and Rx pulse generators. The Tx pulse generator 23 generates pulsed radiation for emission into the tank, whereas the Rx pulse generator 24 generates a reference pulse to be used for calculation of the time difference between the pulses, subsequently to be used in the estimate of the filling level of the tank. The reflected Tx pulse, in this application generally referred to as the echo signal, is received by the antenna 4 , and through a directional coupler 25 forwarded to an amplifier 26 . In the mixer 27 , the amplified echo signal and the Rx signal from the Rx pulse generator 24 are mixed, in order to generate an output signal indicative on the time difference between the pulses.
[0045] The signal processor 21 is preferably a digital signal processor adapted for implementing the various algorithms and functions of the present invention, as discussed more thoroughly in the following. In case the signal processor is digital, a DAC 31 could be provided to convert outgoing digital signals to analog, and a ADC 32 could be provided to convert incoming analog signals to digital.
[0046] The mixed signal is provided to a voltage controlled gain amplifier 28 , a level shifter amplifier 29 and a rectifier and envelop filter 30 , for signal processing, as is per se known from the art.
[0047] In addition, the controlled gain amplifier 28 provides automatic gain control to compensate for the decreased signal strength of echo signals originating from lower levels in the tank, i.e. signals having traveled farther.
[0048] The signal processor 21 is preferably a microprocessor based circuit adapted to receive the incoming signal, as discussed above, and provide as an output a signal or information indicative of the level of material 8 . The functions and algorithms implemented by signal processor 110 , some of which can be embodied in hardware and some of which can be embodied in software, are per se known from the art will not be discussed further in this application.
[0049] The amplification of the received signal is further controlled so that the distance variable amplification is chosen to be set at its maximum value at the level corresponding to the tank bottom at the actual tank. Hereby, the sensitivity is maximized by adjusting the gain based on configured tank height, which provides a very efficient use of the dynamic range of the amplification means.
[0050] The control of the amplification means to this end could be accomplished by introduction of adequate hardware components to the system, such as filters etc, or by controllable hardware components that are manually adapted to the specifics of the tanks in which the system is to be used.
[0051] However, it is also possible to use software control of the amplification means, the software control preferably provided by the signal processor, and preferably by means of embedded control software in the signal processor 21 .
[0052] Preferably, the signal processor provides an amplification ramp for the amplification means 28 , providing an voltage controlled increased amplification over the measuring cycle. However, this amplification ramp is then linearly distributed over the entire available measuring distance Rm of the system, e.g. 30 meters. Such an amplification ramp PA is illustrated in the diagram in FIG. 4 . However, the tank height is normally only a part of the maximally available measuring range Rm. Accordingly, the actually used measuring range R 1 is therefore set at a value corresponding to the estimated or measured tank height, and thereafter the amplification ramp is optimized based on said actually used measuring range R 1 . Such an amplification ramp is illustrated as ramp A in FIG. 4 . The amplification ramp could be a linear amplification ramp from the starting point and the end of the actual range R 1 , as is the case in ramp A. However, depending on the measuring conditions at hand, such as the geometry of the tank, the radar level gauge system used, the filling material to be measured, etc, the ramp could be optimized in various ways. For example, it could sometimes be advantageous to use non-linear ramps, such as an exponential or inversely exponential ramp, in FIG. 4 schematically illustrated as ramps B and C, respectively. Further, it may be advantageous to use ramps comprising two or more separate parts, or ramps starting at a delayed starting point. This is schematically illustrated by ramp D in FIG. 4 .
[0053] In addition, or as an alternative, the amplification of the amplification means 28 may also be controlled using the measuring signals received from the antenna 4 as input.
[0054] With the above-described amplification scheme, the amplification provides the same echo signal strength regardless of the distance, and the dynamic range of the amplification units are optimally used.
[0055] In the system illustrated in FIG. 2 , the second amplification means 28 is actively controlled in the way discussed above. Thus, in this embodiment, the controllable amplification is provided immediately after the mixer 27 . Having the controllable amplification at such an early stage of the signal processing is advantageous, since the noise problem is thereby alleviated.
[0056] However, it is also possible to provide the controllable amplification unit before the mixer 27 . Such an embodiment is illustrated in FIG. 3 , in which the amplifier 26 ′ is controllable in the way discussed thoroughly in the foregoing In this embodiment, the amplification unit 28 ′ need not be controllable. In this embodiment, the noise levels could be even further reduced, alleviating the noise problems even further.
[0057] Even though a pulsed radar level gauge system has been disclosed, the invention could equally well be used in a continuous system, e.g. a FMWC system. Such a system is e.g. disclosed in U.S. Pat. No. 6,107,957, which is hereby incorporated by reference.
[0058] In such systems, a first or reference signal having a varying frequency is generated and the transmitted electromagnetic waves are produced as a function of the frequency of the reference signal. A second signal is then obtained from the electromagnetic waves reflected by the surface of the material and received by the antenna. The two signals should have substantially the same frequency, bat different phases. A phase shift signal is then generated as a function of the phase differences between the reference signal and the second signal over the range of frequencies. The frequency of the phase shift signal is indicative of the distance traveled by the electromagnetic waves between the antenna and the surface of the material being monitored, and thereby of the level of the material.
[0059] Accordingly, in a continuous system the mixer 27 provides an output phase shift signal, having a frequency which is dependent upon the phase difference between continuous signals Tx′ and Rx′, and which is thereby indicative of the distance traveled by the electromagnetic waves and thus of the level of material 8 . Further, the voltage controlled gain amplifier 28 in this case applies a frequency dependent gain to the incoming phase shift signal and provides the amplified phase shift signal at the output. Thus, higher frequency phase shift signals, which have lower amplitudes as a result of the amplitude loss of the electromagnetic waves as they travel further to and from material 8 , are amplified more than are lower frequency signals.
[0060] In a continuous system, the amplification would not be a function of time, but a function of the frequency of the phase shift signal over a desired frequency range. However, the amplification range could still be optimized for the tank height in essentially the same way as discussed in the foregoing for the pulsed system.
[0061] With the present invention, the limited dynamics of the amplification units are used as effectively as possible over the entire measuring distance in actual use. This has proven remarkably efficient, and is specifically advantageous for large measuring distances.
[0062] Specific embodiments of the invention have now been described. However, several alternatives are possible, as would be apparent for someone skilled in the art. For example, many different components may be used for performing the various functions of the level gauge system and the processing circuitry, as would be readily apparent for someone skilled in the art. Further, the proposed amplification control may be used in different types of level gauge systems, and in particular for both continuous and pulsed systems. Such and other obvious modifications must be considered to be within the scope of the present invention, as it is defined by the appended claims. | A radar level gauge system for determining the filling level of a filling material in a tank is disclosed. The system comprises an antenna device for emitting measuring signals towards the surface of the filling material and a receiver device for receiving echo signals from the tank. Further, the system comprises processing circuitry for determining the filling level of the tank based on said echo signal, wherein said processing circuitry is adapted to amplify the received echo signals in dependence of the distance from which the echo signals originates, in such a way that an echo signal from a lower filling level is more amplified than an echo signal from a higher filling level. The processing circuitry is adjustable to optimize the amplification of the echo signal based on the height of the tank. A corresponding processing circuitry and method of operation is also disclosed. | 6 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application claims the benefit under 35 USC 119(e) from U.S. provisional application 61/146,669, filed on Jan. 23, 2009, the disclosure which is incorporated by reference for all purposes as if fully set forth herein.
FIELD OF THE INVENTION
This invention relates to seat cushions used to support individuals in a seated or otherwise reclined position. More particularly, the present invention relates to seat cushions typically used in wheelchairs, which seats structure help preventing a seated handicapped individual from sliding forward on the seat, while preventing the occurrence of decubitus ulcers.
BACKGROUND OF THE INVENTION
Wheelchair seat cushions are designed to perform a number of important functions. A seat cushion should be comfortable and capable of providing proper support for optimal posture and posture control, for a considerable length of time. A seat cushion should create stability and security for the person within the wheelchair. Seat cushions are often designed to help prevent and reduce the incidence of local pressure created by prolonged sitting on the cushion trying to uniformly spread the pressure on the external surface of the seating organs of the individual.
Many prior art attempts have been made to generally or individually fit the shape of the seat cushion to the anatomical shape of the user. For example, U.S. Pat. No. 4,588,229, given to Eric Jay, provides a seat cushion for the human body which comprises a pad comprising a flexible envelope containing a fluid filling material.
U.S. Pat. No. 4,819,286, given to David Beauchamp, provides a dry flotation cushion used on wheelchairs and a method for supporting dry flotation cushion used in wheelchairs. The structure includes a substantially rectangular rigid plate for inserting into the fabric covering of a dry flotation cushion for improving the support provided by a plurality of dry flotation cells when the dry flotation cushion is supported on the side frame members of a wheelchair.
U.S. Pat. No. 7,220,376, given to Thomas Hetzel et al, provides a negative impression of an anatomical portion of a person is captured by forcing the anatomical portion into impression foam to collapse the impression foam into the negative impression. The negative impression is obtained by collapsing the impression foam within the range of constant-force collapse distances, thereby creating the negative impression under conditions which reflect an equally-loaded anatomical portion. This invention is then used to fabricate wheelchair seat cushions.
U.S. Pat. No. 6,009,578, given to Steve Davis, provides a seat cushion for a wheelchair including a resilient wedge-shaped pad having an upper surface at an incline sloping downwardly from a higher end to a lower end. A plurality of spaced apart gel packs are on the upper surface of the resilient wedge-shaped pad. The gel packs closest to the higher end are of a high density, while other gel packs will decrease in density toward the lower end of the resilient wedge-shaped pad. The seat helps preventing a person from sliding off of the wheelchair.
The prior art shaped seat cushion are typically expensive to manufacture and do not necessarily address the problem encountered by handicapped individual, such as elderly individuals, that are sliding forwardly on top of the seat and are not able to pull themselves back. Often, a handicapped individual is not even aware of being in a slid seating position.
Reference is made to FIG. 2 (prior art), which is a cross-sectioned view showing person 10 properly positioned in wheelchair 20 seating system, on seat cushion 50 . The back of person 10 is supported by back 30 of wheelchair 20 . Pelvis 15 supported by both the lower end of back 30 and the end of seat cushion 50 proximal to back 30 .
Reference is also made to FIG. 3 (prior art), which is a cross-sectioned view showing person 10 who has slid forward (in direction 40 ) and thereby improperly positioned in wheelchair 20 seating system, on seat cushion 50 . Pelvis 15 is positioned away from the lower end of back 30 and is and is pointy pressing against seat cushion 50 , thereby causing person 10 to develop decubitus ulcers. Furthermore, the sliding motion cause rubbing of the external surface of pelvis 15 of individual 10 . Furthermore, as person 10 slides on seat cushion 50 , the sliding motion accelerate as vector F H , derived from the weight vector F V of person 10 , is added to the motion forward in direction 40 .
Reference is also made to FIG. 4 (prior art), which is a cross-sectioned view showing person 10 who is seating on wedge seat cushion 52 , which is designed to prevent a seated handicapped individual 10 from sliding forward on seat cushion 52 . Pelvis 15 is positioned away from the lower end of back 30 and is pointy pressing against seat cushion 52 , thereby causing person 10 to develop decubitus ulcers.
There is a need for and it would be advantageous to have a seat cushion that prevents a seated handicapped individual from sliding forward on the seat, while preventing the occurrence of decubitus ulcers. It would be further advantageous for the seat cushion to be simple and inexpensive to manufacture.
SUMMARY OF THE INVENTION
By way of introduction, the principal intentions of the present invention include providing seat cushions that prevent a seated handicapped individual from sliding forward on the seat, while preventing the occurrence of decubitus ulcers. The seat cushions are made of two or more portions made of resilient materials, such as elastomeric materials, whereas the portion of the cushion distal from the back of the wheelchair is more rigid than the portion of the cushion proximal to the back of the wheelchair.
According to the teachings of the present invention there is provided a seat cushion for supporting a person seated on a chair, preferably a wheelchair, including a resilient body having a generally rectangular-cuboid-shape. The resilient body includes a frontal portion having a front end and a rear end, and which is fabricated from materials having a first density, and a rear portion having a front end and a rear end, and is fabricated from materials having a second density. The first density is substantially higher than the second density. Preferably, the resilient body is fabricated out of a sturdy foam material. Preferably, the seat cushion further includes a protective cover wrapping the resilient body.
The frontal portion is disposed distally from the back of the chair, while the rear portion is disposed proximal to the back of the chair. The front end of the rear portion is disposed adjacent to the rear end of the frontal portion.
Preferably, the rear portion is made of viscoelastic materials, to prevent decubitus ulcers.
Preferably, the front end of the rear portion is securely attached to the rear end of the frontal portion. Preferably, the seat cushion is securely attached to the back of the chair.
In variations of the present invention, the seat cushion of the invention further includes one or more intermediate portions, disposed between the fromtal portion and the rear pertion, wherein all of the portions maintain a gradual decrease in density starting at the front portion and ending at the portion.
In variations of the present invention, the frontal portion of the resilient body includes a divider having third density, wherein the divider laterally subdivides the frontal portion into two generally symmetric sections, wherein each of the symmetric sections facilitates comfort and stability for a respective thigh of the person sitting in the chair. The third density is higher than the first density.
In variations of the present invention, the frontal portion of the resilient body includes a divider having third density and a top layer having a fourth density, wherein the divider is disposed adjacently above the frontal portion and laterally subdivides the frontal portion into two generally symmetric sections. The top layer is disposed adjacently above the divider, the frontal portion and optionally the rear portion. Each of the symmetric sections facilitates comfort and stability for a respective thigh of the person sitting in the chair. The third density is substantially higher than the first density and preferably, the forth density is lower than the third density. Preferably, the top layer extends to the dimensions of the seat cushion.
In variations of the present invention, the frontal portion of the resilient body includes a divider having third density and a bottom layer having a fourth density, wherein the divider is disposed adjacently below the frontal portion and laterally subdivides the frontal portion into two generally symmetric sections. The bottom layer is disposed adjacently below the divider, the frontal portion and optionally the rear portion. Each of the symmetric sections facilitates comfort and stability for a respective thigh of the person sitting in the chair. The third density is substantially higher than the first density and preferably, the forth density is higher than the third density. Preferably, the top layer extends to the dimensions of the seat cushion.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will become fully understood from the detailed description given herein below and the accompanying drawings, which are given by way of illustration and example only and thus not limitative of the present invention, and wherein:
FIG. 1 illustrates a wheelchair with a seat cushion, according to embodiments of the present invention;
FIG. 2 (prior art) is a cross-sectioned view showing a person properly positioned in a wheelchair seating system;
FIG. 3 (prior art) is a cross-sectioned view showing a person who has slid forward and thereby improperly positioned in a wheelchair seating system;
FIG. 4 (prior art) is a cross-sectioned view showing a person who is seating on a wedge seat cushion, which is designed to prevent a seated handicapped individual from sliding forward on the seat;
FIG. 5 is a perspective view illustration of a seat cushion, according to variations of the present invention;
FIG. 6 is a cross-sectioned view showing a person properly positioned and held in a wheelchair seating system having the seat cushion shown in FIG. 5 ;
FIG. 7 is a graphical chart showing the rigidity of the seat cushion shown in FIG. 5 , vs. the distance of a position on the seat cushion from its front end;
FIG. 8 is a perspective view illustration of a seat cushion, according to other variations of the present invention;
FIG. 9 is a graphical chart showing the rigidity of the seat cushion shown in FIG. 8 , vs. the distance of a position on the seat cushion from its front end;
FIG. 10 is a perspective view illustration of a seat cushion, according to another variation of the present invention;
FIG. 11 is a perspective view illustration of a seat cushion, according to yet another variation of the present invention;
FIG. 12 is a perspective view illustration of a seat cushion, according to still another variation of the present invention, the seat cushion being in a non-seated state; and
FIG. 13 is a perspective view illustration of the seat cushion shown in FIG. 11 , the seat cushion being in a seated state.
DETAILED DESCRIPTION OF THE INVENTION
The present invention now will be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided, so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art.
Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The methods and examples provided herein are illustrative only and not intended to be limiting.
By way of introduction, the principal intentions of the present invention include providing seat cushions that prevent a seated handicapped individual from sliding forward on the seat.
Reference is now made to the drawings. FIG. 1 illustrates a wheelchair 20 with seat cushion 100 , according to variations of the present invention. FIG. 5 is a perspective view of seat cushion 100 (having the cushion cover removed). Seat cushion 100 has a generally rectangular-cuboid-shaped body that includes a frontal portion 120 and a rear portion 110 . Frontal portion 120 and rear portion 110 are made of resilient materials, wherein frontal portion 120 is more rigid than rear portion 110 .
Rear portion 110 has a front end and a rear end, wherein the rear end of rear portion 110 is proximal to back 30 of wheelchair 20 and the front end of rear portion 110 is most distal from back 30 of wheelchair 20 . Frontal portion 120 has a front end and a rear end, wherein the front end of frontal portion 120 is most distal from back 30 of wheelchair 20 and the rear end of frontal portion 120 is most proximal to back 30 of wheelchair 20 . The front end of rear portion 110 is disposed adjacent to the rear end of frontal portion 120 and preferably, securely attached to the rear end of frontal portion 120 .
FIG. 6 is a cross-sectioned view showing person 10 properly positioned and held in wheelchair 20 seating system, utilizing seat cushion 100 . The back of person 10 is supported by back 30 of wheelchair 20 . Pelvis 15 supported by both the lower end of back 30 and rear portion 110 of seat cushion 100 , disposed proximal to back 30 . Frontal portion 120 , being more rigid than rear portion 110 , further supports pelvis 15 such that frontal portion 120 prevents pelvis 15 from sliding forward (direction 40 in FIG. 3 ) on seat cushion 100 .
FIG. 7 is a graphical chart showing the rigidity of seat cushion 100 , vs. the distance of positions on seat cushion 100 from the front end of seat cushion 100 . Part A exemplifies the rigidity of frontal portion 120 and part B exemplifies the rigidity of rear portion 110 .
FIG. 8 is a perspective view of seat cushion 200 (having the cushion cover removed). Seat cushion 200 has a generally rectangular-cuboid-shaped body that includes a frontal portion 230 , a middle portion 220 and a rear portion 210 , all of which are made of resilient materials. Frontal portion 230 is more rigid than middle portion 220 and middle portion 220 is more rigid than rear portion 210 .
Rear portion 210 has a front end and a rear end, wherein the rear end of rear portion 210 is proximal to back 30 of wheelchair 20 and the front end of rear portion 210 is most distal from back 30 of wheelchair 20 . Middle portion 220 has a front end and a rear end, wherein the front end of middle portion 220 is most distal from back 30 of wheelchair 20 and the rear end of middle portion 220 is most proximal to back 30 of wheelchair 20 . Frontal portion 230 has a front end and a rear end, wherein the front end of frontal portion 230 is most distal from back 30 of wheelchair 20 and the rear end of frontal portion 230 is most proximal to back 30 of wheelchair 20 .
The front end of rear portion 210 is disposed adjacent to the rear end of middle portion 220 and preferably, securely attached to the rear end of middle portion 220 . The front end of middle portion 220 is disposed adjacent to the rear end of front portion 230 and preferably, securely attached to the rear end of front portion 230 .
FIG. 9 is a graphical chart showing the rigidity of seat cushion 200 , vs. the distance of positions on seat cushion 200 from the front end of seat cushion 100 . Part P exemplifies the rigidity of frontal portion 230 , part Q exemplifies the rigidity of middle portion 220 and part R exemplifies the rigidity of rear portion 210 .
Reference is now made to FIG. 10 , which is a perspective view of seat cushion 300 (having the cushion cover removed). Seat cushion 300 has a generally rectangular-cuboid-shaped body that includes frontal portion 320 and rear portion 310 , all of which are made of resilient materials. Frontal portion 320 is more rigid than rear portion 310 .
Rear portion 310 has a front end and a rear end, wherein the rear end of rear portion 310 is proximal to back 30 of wheelchair 20 and the front end of rear portion 310 is most distal from back 30 of wheelchair 20 . Frontal portion 320 has a front end and a rear end, wherein the front end of frontal portion 320 is most distal from back 30 of wheelchair 20 and the rear end of frontal portion 320 is most proximal to back 30 of wheelchair 20 . The front end of rear portion 310 is disposed adjacent to the rear end of front portion 320 and preferably, securely attached to the rear end of front portion 320 .
Frontal portion 320 further includes a divider 340 , having a front end and a rear end, wherein divider 340 is more rigid than frontal portion 320 ; wherein the front end of divider 340 is preferably flush with the front end of frontal portion 320 , and the rear end of divider 340 is preferably flush with the rear end of frontal portion 320 . Preferably, divider 340 laterally subdivides frontal portion 320 into two generally symmetric sections 320 a and 320 b . Divider 340 further enhances seat cushion 300 such that divider 340 further the sliding forward of a seated individual 10 .
Reference is now made to FIG. 11 , which is a perspective view illustration of a seat cushion 400 (having the cushion cover removed), according to another variation of the present invention, seat cushion 400 being in a non-seated state. Seat cushion 400 has a generally rectangular-cuboid-shaped body that includes frontal portion 420 and rear portion 410 , all of which are made of resilient materials. Frontal portion 420 is more rigid than rear portion 410 .
Rear portion 410 has a front end and a rear end, wherein the rear end of rear portion 410 is proximal to back 30 of wheelchair 20 and the front end of rear portion 410 is most distal from back 30 of wheelchair 20 . Frontal portion 420 has a top face, a bottom face, a front end and a rear end, wherein the front end of frontal portion 420 is most distal from back 30 of wheelchair 20 and the rear end of frontal portion 420 is most proximal to back 30 of wheelchair 20 . The front end of rear portion 410 is disposed adjacent to the rear end of front portion 420 and preferably, securely attached to the rear end of front portion 420 .
Seat cushion 400 further includes a divider 440 , which divider 440 is more rigid than frontal portion 420 . Divider 440 is disposed adjacently above frontal portion 420 and a top layer 450 , attached to the top surface frontal portion 420 . Divider 440 is extends from approximately the front end of frontal portion 420 to generally the rear end of frontal portion 420 . Preferably, top layer 450 is less rigid than divider 440 . Preferably, divider 440 is disposed generally at the lateral middle of frontal portion 420 .
When an individual 10 seats on top of top layer, top layer 450 presses divider 440 downwardly, against divider 440 and thereby against the top face of front portion 420 . Since top layer 450 is softer than divider 440 , a protrusion 452 is formed in the front section of top layer 450 . Divider 440 further enhances seat cushion 400 as protrusion 452 further prevents the sliding forward of the seated individual 10 .
Reference is now made to FIG. 12 , which is a perspective view illustration of a seat cushion 500 (having the cushion cover removed), according to still another variation of the present invention, seat cushion 500 being in a non-seated state. FIG. 13 is a perspective view illustration of seat cushion 500 being in a seated state. Seat cushion 500 has a generally rectangular-cuboid-shaped body that includes frontal portion 520 and rear portion 510 , all of which are made of resilient materials. Frontal portion 520 is more rigid than rear portion 510 .
Rear portion 510 has a front end and a rear end, wherein the rear end of rear portion 510 is proximal to back 30 of wheelchair 20 and the front end of rear portion 510 is most distal from back 30 of wheelchair 20 . Frontal portion 520 has a top face, a bottom face, a front end and a rear end, wherein the front end of frontal portion 520 is most distal from back 30 of wheelchair 20 and the rear end of frontal portion 520 is most proximal to back 30 of wheelchair 20 . The front end of rear portion 510 is disposed adjacent to the rear end of front portion 520 and preferably, securely attached to the rear end of front portion 520 .
Seat cushion 500 further includes a divider 540 , which divider 540 is more rigid than frontal portion 520 . Divider 540 is disposed adjacently below frontal portion 520 and bottom layer 550 , pressing divider 540 upwards, against the bottom face of front portion 520 . Preferably, bottom layer 550 is more rigid than divider 540 . Preferably, divider 540 is disposed generally at the lateral middle of frontal portion 520 .
When an individual 10 seats on top of seat cushion 500 , the flat hard top of wheelchair 20 presses bottom layer 550 upwardly, in the general direction 545 . Thereby, bottom layer 550 presses divider 540 upwardly, against the bottom face of front portion 520 . Since front portion 520 is softer than divider 540 , divider 540 pushes the middle section of the bottom face of front portion 520 upwardly, whereby causing the middle section of the top face of front portion 520 upwardly, forming a protrusion 522 of the top face of front portion 520 . Divider 540 further enhances seat cushion 500 as protrusion 522 further prevents the sliding forward of the seated individual 10 .
In variations of the present invention and according to the preferred embodiment of the present invention, bottom layer 550 is substantially more rigid than divider 540 . At assembly time, divider 540 is pressed upwardly by bottom layer 550 , in the general direction 545 , against the bottom face of front portion 520 . Since front portion 520 is softer than divider 540 , divider 540 pushes the middle section of the bottom face of front portion 520 upwardly, whereby causing the middle section of the top face of front portion 520 upwardly, forming a protrusion 522 of the top face of front portion 520 . All layers are securely attached in that position, for example by glue.
It should be noted that in other variations of the seat cushion of the present invention, the seat cushion is composed of any number of multiple resilient portions, each having a density that decreases from portion to portion, as the portion is disposed nearer to back 30 of wheelchair 20 .
It should be noted that the elastic portions of the seat cushion of the present invention can be made of any elastic materials, including, but not limited to, elastomeric materials, for example, viscoelastic materials.
In variations of the present invention, the rigidity of all portions of seat cushion 500 , 400 , 300 , 200 and/or seat cushion 100 are fitted to the weight range of seated individual 10 .
In variations of the present invention, more rigid margins are add to the sides of seat cushion 500 , 400 , 300 , 200 and/or seat cushion 100 , to prevent sideways sliding of a seated individual 10 .
In variations of the present invention, more rigid margins are add to the sides of seat cushion 500 , 400 , 300 , 200 and/or seat cushion 100 are coupled to a chair which is not a wheelchair, to prevent seated individual 10 from sliding off the seat.
Preferably, seat cushions 100 , 200 , 300 , 400 and/or 500 are securely attached to back 30 of wheelchair 20 .
The invention being thus described in terms of several embodiments and examples, 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. | Seat cushions that prevent a seated handicapped individual from sliding forward on the seat, while preventing the occurrence of decubitus ulcers. The seat a seat cushion includes a resilient body having a generally rectangular-cuboid-shape. The resilient body includes a frontal portion having a front end and a rear end, and which is fabricated from materials having a first density, and a rear portion having a front end and a rear end, and is fabricated from materials having a second density. The first density is substantially higher than the second density. Preferably, the resilient body is fabricated out of a sturdy foam material. Preferably, the seat cushion further includes a protective cover wrapping the resilient body. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to flexural joints for rotating or pivoting members and, more particularly, joints of the type which may be used in pivotal hand tools.
2. Description of the Prior Art
Flexural pivots are used to overcome a number of disadvantages associated with other types of pivot joints. Among the advantages of flexural pivots are the elimination of friction, backlash and wear, lack of requirement for lubrication, insensitivity to contamination and the ability to operate over a wide range of environmental conditions.
One prior type of flexural pivot is disclosed, for example, in U.S. Pat. No. 3,807,029. While that joint affords the above-mentioned advantages, it also has disadvantages. It involves the use of two bushings and two different flexible blade elements. This means that there are four distinct parts which must be fabricated, stocked and assembled to form the joint. Furthermore, the joint, when thus assembled, must in turn be assembled to the pivoting or rotating members of the particular application. Also, in the assembly of the pivot joint, the flexible blade elements must be brazed to the bushings, a costly and time-consuming procedure.
It is known to provide a flexural pivot joint which uses flexible blade elements of substantially identical construction, such an arrangement being disclosed, for example, in U.S. Pat. No. 5,061,107. However, this arrangement also requires the use of two bushings, and the blade ends must be secured by electron beam welding or epoxy adhesive to the bushings.
Another drawback of such prior flexural pivot joints is that they typically have a relatively low compression capacity and, therefore, if substantial axial forces are impressed on the joint, the flexible elements could be permanently deformed, thereby effectively destroying the joint.
SUMMARY OF THE INVENTION
It is a general object of the present invention to provide an improved flexural pivot joint which avoids the disadvantages of prior pivot joints while affording additional structural and operating advantages.
An important feature of the invention is a provision of a flexural pivot joint which is of simple and economical construction and is characterized by ease of assembly.
In connection with the foregoing feature, a further feature of the invention is the provision of a pivot joint of a type set forth, which minimizes the number of unique parts.
A further feature of the invention is the provision of a pivot joint of the type set forth, which includes flexible blade elements which can be connected directly to levers or other pivoting members of a particular application.
A still further feature of the invention is the provision of a pivot joint of the type set forth which has improved compression capacity.
Yet another feature of the invention is a provision of a pivot joint of the type set forth, wherein the joint can be assembled without the use of welding or adhesives.
Certain ones of these and other features of the invention are attained by providing a flexural pivot joint comprising first and second pivoting members pivotally movable relative to each other about a common pivot axis, a first generally Z-shaped flexible element defining a first plane which includes the axis, the first element having ends respectively connected to the first and second pivoting members, and a second generally Z-shaped flexible element spaced from the first element and defining a second plane which includes the axis, the second element having ends respectively connected to the first and second pivoting members.
Further features of the invention are attained by providing a flexural pivot joint comprising first and second elongated lever members each having a handle portion and a jaw portion and a neck portion interconnecting the handle portion and the jaw portion, each of the neck portions including a cylindrical surface portion, the lever members being crossed with the neck portions overlapping so that the cylindrical surface portions are coaxial with a common pivot axis, and first and second spaced-apart flexible elements respectively defining mutually perpendicular planes, each of the elements having opposite ends respectively directly connected to the cylindrical surface portions of the lever members.
Still further features of the invention are attained by providing a flexural pivot joint comprising first and second pivoting members respectively defining first and second cylindrical surface portions coaxial with a common pivot axis for relative pivotal movement about the axis, and four spaced-apart flexible elements respectively defining planes each including the axis, each of the flexible elements having opposed end portions respectively connected to the first and second pivoting members at opposite sides of the axis.
The invention consists of certain novel features and a combination of parts hereinafter fully described, illustrated in the accompanying drawings, and particularly pointed out in the appended claims, it being understood that various changes in the details may be made without departing from the spirit, or sacrificing any of the advantages of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
For the purpose of facilitating an understanding of the invention, there is illustrated in the accompanying drawings a preferred embodiment thereof, from an inspection of which, when considered in connection with the following description, the invention, its construction and operation, and many of its advantages should be readily understood and appreciated.
FIG. 1 is a top plan view of a pair of cutters utilizing a flexural pivot joint in accordance with one embodiment of the present invention;
FIG. 2 is an enlarged, fragmentary, perspective, exploded view of the pivot joint of the cutters of FIG. 1;
FIG. 3 is an enlarged, fragmentary top plan view of the joint portion of the cutters of FIG. 1, rotated 90° counterclockwise;
FIG. 4 is a fragmentary view in vertical section taken along the line 4--4 in FIG. 3;
FIG. 5 is an exploded perspective view of another embodiment of the flexural pivot joint of the present invention;
FIG. 6 is a view similar to FIG. 2 of a cutter tool incorporating the flexural pivot joint of FIG. 5;
FIG. 7 is a an enlarged top plan view of the pivot joint of FIG. 5 in its assembled condition;
FIG. 8 is a top plan view of the pivot joint in accordance with another embodiment of the invention;
FIG. 9 is a perspective view of the flexible blades of the pivot joint of FIG. 8 with the bushing removed;
FIG. 10 is a view in vertical section taken along the line 10--10 in FIG. 8; and
FIG. 11 is an enlarged, fragmentary, sectional view of a preferred form of engagement of a flexible blade with a pivoting member in a pivot joint in accordance with the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, there is illustrated a cutter tool, generally designated by the numeral 20, which incorporates a pivot joint 30 constructed in accordance with a first embodiment of the present invention. The cutter tool 20 is of standard pivoting-jaw construction, including a pair of lever members 21 and 21A which are similar in construction. Accordingly, the parts of each of the lever members 21 and 21A have been assigned the same reference numbers, with the reference numbers on the lever member 21A having the suffix "A" for ease of distinction. Referring now also to FIG. 2, the lever member 21 has a handle portion 22 at one end thereof, a jaw portion 23 at the opposite end thereof and a neck portion 24 interconnecting the handle and jaw portions 22 and 23. The neck portion 24 is thinner than the remainder of the lever member 21, having a recessed surface 25. Formed through the neck portion 24 is a cylindrical bore 26 defining a cylindrical surface 27 having two, axially extending grooves 28 and 29 formed therein at locations spaced apart by substantially 90°. The lever member 21A is similar to the lever member 21, having corresponding portions 22A--29A, the only difference being that the grooves 28A and 29A are, respectively, disposed at diametrically opposite locations from the grooves 28 and 29.
The pivot joint 30 is formed, in part, by the neck portions 24 and 24A of the lever members 21 and 21A and, in part, by two flexible blade elements 31 and 31A. The blade elements 31 and 31A are of identical construction, wherefore only one will be described in detail, and like parts of both are assigned the same reference numbers but, for purposes of distinguishing the two, the reference numbers of the blade element 31A have an "A" suffix. The flexible blade element 31 is in the form of a substantially flat, thin plate or blade which is substantially "Z"-shaped, having an end portion 32 projecting in one direction and an end portion 33 projecting in the opposite direction and a curved knee portion 34 interconnecting the end portions 32 and 33. An arcuate recess 35 is formed at the inner curve of the knee portion 34 to help minimize stress concentrations. Each of the end portions 32 and 33 is substantially rectangular in shape, these end portions respectively having formed at their distal edges elongated coupling ribs or beads 36 and 37, each extending the length of the associated distal edge and being thicker than the blade element 31 and dimensioned for mating engagement in the grooves 28, 29, 28A and 29A in the lever members 21 and 21A.
Referring also to FIGS. 3 and 4, in assembly the flexible blade elements 31 and 31A are first attached to the lever member 21. More specifically, the coupling rib 37 is press-fitted in the groove 28 and the coupling rib 37A is press-fitted in the groove 29, so that the flexible blade elements 31 and 31A respectively define substantially perpendicular planes, the blade elements 31 and 31A crossing at their knee portions 34 and 34A so as to provide clearance therebetween. It will be appreciated that, preferably, the ribs 37 and 37A have substantially the same length as the thickness of the neck portion 24 and each of the grooves 28 and 29 is shaped and dimensioned so that the ribs 37 and 37A cannot be remove(therefrom in a radial direction.
The lever member 21A is then crossed over the lever member 21 with the recessed surfaces 25 and 25A disposed in facing relationship and with the cylindrical bores 26 and 26A coaxially arranged. The coupling ribs 36 and 36A of the blade elements 31 and 31A are then, respectively, press-fitted in the grooves 28A and 29A of the lever member 21A, bringing the pivot joint 30 to the assembled condition illustrated in FIGS. 1, 3 and 4. Thus, there is provided a flexural pivot joint which utilizes only a single unique part (the flexible blade element 31), which must be assembled with the lever members of the cutter tool 20 to form the joint. Thus, only one part need be stocked in addition to the lever members 21 and 21A. Furthermore, the blade elements 31 and 31A can be assembled to the lever members 21 and 21A without the use of adhesives or attachment techniques, such as welding, brazing or the like, thereby greatly simplifying the assembly of the pivot joint 30.
In a preferred embodiment of the invention, the blade elements 31 and 31A are arranged, as illustrated in FIGS. 1 and 3, with their planes respectively disposed at substantially 45° angles to the longitudinal axis of the tool 20. Preferably, the parts are arranged so that, in the normal rest condition of the tool 20, the handle portions 22 and 22A and the jaw portions 23 and 23A are held apart by the spring factor of the pivot joint 30, being automatically returned to this initial position after performance of the cutting operation by a user.
Referring now also to FIGS. 5-7, there is illustrated a pivot joint generally designated by the numeral 40, constructed in accordance with another embodiment of the invention. The pivot joint 40 utilizes the same flexible blade elements 31 and 31A used in the pivot joint 30. However, in this case the blade elements 31 and 31A are connected to a split bushing 41 having two identical, substantially semi-cylindrical bushing halves 42 and 43. Each of the bushing halves 42 and 43 has formed on the inner part-cylindrical surface thereof two elongated grooves 44 extending axially thereof and circumferentially spaced apart by substantially 90°.
In assembly, the blade elements 31 and 31A are again crossed in the same manner as was described above in connection with the pivot joint 30, and the coupling ribs 36 and 36A are, respectively, press-fitted in the grooves 44 on the bushing half 42, while the coupling ribs 37 and 37A are, respectively, press-fitted in the grooves 44 on the bushing half 43, resulting in the assembled pivot joint 40 illustrated in FIG. 7. When thus assembled, it can be seen that there is a clearance gap 48 between the bushing halves 42 and 43 to accommodate limited relative pivotal movement thereof. There results a complete pivot joint 40 which can then be assembled, as a unit, in pivoting members of an associated application, such as a cutter tool 45 (FIG. 6).
The cutter tool 45 is substantially the same as the cutter tool 20, described above in connection with FIG. 1, being comprised of two lever members 46 and 46A having coaxial cylindrical bores 47 and 47A formed through the neck portions thereof. The lever members 46 and 46A are, respectively, substantially identical to the lever members 21 and 21A, described above, except that in this case the bores 47 and 47A do not have grooves formed therein. Thus, it will be appreciated that the lever members 46 and 46A may be identical in construction. In assembly, the lever members 46 and 46A are crossed in overlapping position in the same manner as was described above in connection with the cutter tool 20, and the split bushing halves 42 and 43 are, respectively, press-fitted into the cylindrical bores 47 and 47A.
It can be seen that there is again provided a pivot joint 40 which is of simple and economical construction and characterized by ease of assembly. In this case, the pivot joint itself includes two unique members, viz., the blade element 31 and the bushing half 42, but the lever members 46 and 46A are now identical, so that the total number of unique parts needed to assemble the cutter tool 45 is the same as the case of the cutter tool 20.
Referring now to FIGS. 8-10, there is illustrated a pivot joint 50 in accordance with another embodiment of the invention. The pivot joint 50 includes two cylindrical bushings 51 and 51A which are substantially identical in construction and have like numbers assigned to like parts, with the parts of the bushing 51A bearing the suffix "A". The bushing 51 has eight equiangularly spaced-apart grooves 52 formed in the inner surface thereof and extending axially the length thereof. The pivot joint 50 also includes four flexible blade elements, including substantially identical blade elements 53 and 53A, each of which is Z-shaped and is substantially similar to the blade elements 31 and 31A described above, except that the shape is slightly altered to afford adequate clearance for other parts of the pivot joint 50. Each of the blade elements 53 and 53A has the coupling ribs 36 and 37 (36A and 37A) respectively at the opposite ends thereof.
The pivot joint 50 also includes a flexible blade element 55, which is generally rectangular in shape, having a rectangular opening 56 therethrough centrally thereof, and having rectangular notches 57 formed respectively in the opposite long side edges thereof, intermediate the ends thereof. Formed along one of these long side edges, at opposite ends of the notch 57, are coupling ribs or beads 58, while like ribs or beads 59 are formed along the opposite long side edge. The pivot joint 50 also includes a flexible blade element 60, which is also substantially rectangular in shape and has a rectangular opening 61 formed therethrough centrally thereof. The blade element 60 has rectangular notches 62, respectively formed centrally of the opposite end edges thereof, and rectangular notches 63, respectively formed centrally of the opposite side edges thereof. Formed on one of these side edges are cylindrical coupling ribs or beads 64, while coupling ribs 65 are formed on the opposite side edge.
Referring in particular to FIGS. 9 and 10, the blade elements 53, 53A, 55 and 60 are arranged with the blade elements 53 and 53A crossed in substantially the same manner as was described above in connection with FIGS. 1-4 and extending through the central rectangular opening 61 of the blade element 60. The blade element 60, in turn, extends through the central rectangular opening 56 of the blade element 55. Then, the coupling ribs of the flexible blade elements are press-fitted in corresponding ones of the grooves 52, 52A of the bushings 51, 51A, so that the blade elements 53 and 53A respectively define perpendicular planes and the blade elements 55 and 60 respectively define perpendicular planes, the planes all being equiangularly spaced apart. In particular, the coupling ribs 36 and 36A and the coupling ribs 58, 59, 64 and 65 at one end of the blade elements 55 and 60 are all press-fitted in the grooves 52 of the bushing 51, while the coupling ribs 37 and 37A and the coupling ribs 58, 59, 64 and 65 at the opposite ends of the blade elements 55 and 60 are press-fitted in the grooves 52A of the bushing 51A.
The pivot joint 50, when thus assembled, can be similarly mounted in any desired pivotal application, such as a pivoting hand tool or the like, with the bushing 51 being press-fitted in a complementary bore in one of the pivoting members and the bushing 51A being press-fitted in a complementary bore in the other one of the pivoting members. It will be appreciated that, in the assembled pivot joint 50, the blade elements 53, 53A, 55 and 60 are all dimensioned so that they will be spaced from one another. However, because there are four blade elements, the pivot joint 50 has substantially increased spring factor and compression capacity.
In each of the pivot joints 30, 40 and 50, the ribs or beads 36, 37, 58, 59, 64 and 65 of the several flexible blade elements, and the grooves in which they are fitted, are all illustrated, for simplicity and convenience, as being part-cylindrical in transverse cross section, with the grooves having a circumferential extent greater than 180° so as to prevent removal of the ribs from the grooves in a radial direction. However, in the preferred embodiment, the ribs and corresponding grooves of each of the pivot joints 30, 40 and 50 will be constructed in accordance with the configuration illustrated in FIG. 11.
More specifically, in FIG. 11 there is illustrated a portion of a pivoting member 70, which may be representative of a lever member neck portion 24 or a pivot joint split bushing half 42 or 43 or a cylindrical bushing 51. The pivoting member 70 has a cylindrical inner surface 71 having formed therein a groove 72, which is generally part-cylindrical in shape and defines an entrance gap 73 thereinto which has a width substantially less than the maximum diameter of the groove 72. Formed at the bottom of the groove 72 diametrically opposite the entrance gap 73 is an arcuate, substantially part-cylindrical bead 74 which projects radially into the groove 72. There is received in the groove 72 a complementarily-shaped coupling rib 75 formed at the distal end of an associated flexible blade element 76, which may be any of the flexible blade elements 31, 55 or 60. The coupling rib 75 has a maximum diameter or thickness which is substantially greater than the thickness of the blade element 76 and, indeed, the width of the entrance gap 73 is substantially greater than the thickness of the blade element 76. The coupling rib 75 has formed in the distal end thereof, diametrically opposite the blade element 76, a part-cylindrical, arcuate recess 77 dimensioned for accommodating therein the bead 74 when the rib 75 is press-fitted in the groove 72. The recess 77 serves to define a pair of rounded projections 78 and 79 on the coupling rib 75. Preferably, the radius of the recess 77 is greater than that of the bead 74 so that there is a slight clearance space between the bead 74 and the projections 78 and 79.
In use, it will be appreciated that the projections 78 and 79 are, respectively, engageable with opposite sides of the bead 74 to prevent significant pivoting or rotational movement of the coupling rib 75 about its axis within the groove 72. The significant clearance splice between the opposite edges of the groove 72 at the entrance gap 73 and the blade element 76 accommodates a very slight rotational movement of the coupling rib 75, and also serves to accommodate flexural or pivotal movement of the blade element 76 relative to the coupling rib 75 about the junction therebetween.
While, in the illustrated embodiments, the pivot joint 40 has flexible blade elements coupled to bushing halves which are split along a diametral plane, it will be appreciated that, if desired, the flexible blade elements of the pivot joint 40 could be coupled to cylindrical, axially spaced-apart bushings of the general type used in the pivot joint 50. In like manner, the pivot joint 50 could, if desired, be constructed utilizing diametrically split, part-cylindrical bushing halves rather than axially spaced-apart cylindrical bushings. Also, in the illustrated embodiments, the pivot joints 30, 40, and 50 have been shown as applied to pivoting hand tools, it will be appreciated that they could be used in any number of other applications for joining pivoting members.
In constructional models of the invention, the flexible blade elements 31, 53, 55 and 60 are all formed of a suitable metal, such as a spring steel or the like, but it will be appreciated that any material having the requisite flexibility and strength could be utilized. While, in the preferred embodiments, these flexible blade elements are coupled to the associated pivoting members by press-fitting in associated grooves, they could be secured by other means. Similarly, the bushings 41 and 51 could be secured in the associated lever members or other pivoting members by means other than press fitting, if desired.
From the foregoing, it can be seen that there has been provided an improved flexural pivot joint which is of simple and economical construction, utilizing a minimal number of unique parts and characterized by ease of assembly and improved spring factor and compression capacity. | A flexural pivot joint includes two pivoting members, which may be levers of a pivotal hand tool, and two substantially identical flexible blade elements, each substantially Z-shaped and having opposite ends respectively connected to the pivoting members. In particular, each blade end has an enlarged coupling portion adapted to be press-fitted in a groove which may be formed either directly in the lever member or in a bushing which is fixed to the lever member. Each bushing may be either a full cylinder or a split cylinder. In one embodiment the joint includes, in addition to the Z-shaped elements, two non-identical flexible elements, the four elements being equiangularly spaced. The grooves and coupling portions may be complementarily shaped, with each groove having a bead receivable in a recess in the coupling portion to inhibit relative rotation. | 8 |
FIELD OF THE INVENTION
The present invention relates to an exposure technique for exposing a substrate coated with a photosensitive material to a pattern in manufacturing a device, such as a semiconductor device, a liquid crystal display device, or the like, and, more particularly, to an exposure technique using an immersion method.
BACKGROUND OF THE INVENTION
The manufacturing process of a semiconductor device with a submicroscopic pattern, such as an LSI, VLSI, or the like, employs a reduction projection exposure apparatus, which reduces and projects a pattern formed on a mask and transfers it onto a substrate coated with a photosensitive agent. Along with an increase in the integration degree of semiconductor devices, finer patterns have been demanded. Concurrently, with development of resist processes, measures have been taken against exposure apparatuses for miniaturizing patterns.
To improve the resolution of an exposure apparatus, a method of shortening the exposure wavelength or a method of increasing the numerical aperture (NA) of the projection optical system is generally employed.
As for the exposure wavelength, a KrF excimer laser with an oscillation wavelength of 365-nm i-line to recently around 248 nm, and an ArF excimer laser with an oscillation wavelength around 193 nm have been developed. A fluorine (F 2 ) excimer laser with an oscillation wavelength around 157 nm is also under development.
As another technique for increasing the resolution, a projection exposure method using immersion is receiving attention. Conventionally, the space between the final surface of a projection optical system and a substrate (e.g., a wafer) to be exposed is filled with a gas. Immersion performs projection exposure by filling this space with a liquid. For example, assume that pure water (whose refractive index is 1.33) is to be provided to the space between a projection optical system and a wafer, and the maximum incident angle of light beams which form an image on the wafer in immersion is equal to that in a conventional method. In this case, the resolution in immersion becomes 1.33 times higher than that in the conventional method, even when a light source having the same wavelength is used in each method. This is equivalent to an increase in NA of the projection optical system in the conventional method by a factor of 1.33. Immersion makes it possible to obtain a resolution whose NA is 1 or more, which cannot be attained by the conventional method.
To fill the space between the final surface of a projection optical system and a wafer surface, mainly, two types of methods have been proposed.
One of them is a method of placing the final surface of the projection optical system and the entire wafer in a liquid tank. Japanese Patent Laid-Open No. 6-124873 discloses an exposure apparatus using this method.
The other is a method of supplying a liquid only to the space between the projection optical system and the wafer surface, i.e., a local fill method. Publication WO99/49504 discloses an exposure apparatus using this method.
In the method disclosed in Japanese Patent Laid-Open No. 6-124873, a liquid may splash about when a wafer moves at high velocity, and equipment is required to recover such splashes. Also, micro-bubbles caused by the wavy liquid surface my adversely affect the imaging performance. In addition, this method may increase the complexity and size of the apparatus.
In the method disclosed in WO99/49504, assume that the gap between a wafer and a projection optical system is small. In this case, even when a nozzle is directed toward the gap, and a liquid is supplied to the gap, the liquid discharged from the nozzle does not flow into the gap, and a gas remains in the gap. For this reason, satisfactory immersion cannot be performed. A liquid having failed to flow into the gap collides with the perimeter of a projection lens and escapes externally. Equipment for recovering the liquid needs to be provided around the perimeter, and the size of the exposure apparatus increases. Even if a liquid can be supplied into the small gap, since the flow resistance inside the gap is larger than that outside the gap, the flow velocity of the liquid discharged from the nozzle is much higher than that in the gap. For this reason, the flow velocity changes excessively at the tip of the nozzle or at a portion where the liquid collides with the perimeter of the projection lens, the flow is greatly disturbed, and air bubbles may be generated. These air bubbles may enter the gap between the projection lens and the wafer, may prevent transmission of light, and may adversely affect the imaging performance of the exposure apparatus.
In the method disclosed in WO99/49504, a liquid supplied onto the wafer needs to be recovered at least for every wafer replacement, and the productivity of the apparatus must be sacrificed to recover the liquid. Recovery of a liquid on the wafer means recovering a liquid below the projection lens. For this reason, a part of the lower surface of the projection lens can get wet at every wafer replacement, another part can be coated with a thin liquid film, and still another part can directly be exposed to the outer air. The environment surrounding the projection lens and wafer contains impurities in larger amounts in comparison with the supplied liquid, and a liquid staying on the lower surface of the projection lens may absorb an impurity contained in the outer air. The liquid staying on the lower surface of the projection lens evaporates to the outer air, and the impurity originally contained in the liquid or an impurity absorbed from the outer air condenses in the liquid. As a result, an impurity may be attached to the surface of the projection lens to cause clouds or the impurity may remain as a residue after the evaporation/drying of the liquid on the surface of the projection lens to cause clouds.
SUMMARY OF THE INVENTION
The present invention has been made in consideration of the above-mentioned problems, and has as its object to increase the practicality of an exposure technique using an immersion method and, for example, more reliably fill the gap between the final surface of a projection optical system and a substrate with a liquid, suppress contamination on the final surface of the projection optical system, simplify the structure of an exposure apparatus, reduce the size of the exposure apparatus, or the like.
According to the first aspect of the present invention, there is provided an exposure apparatus which exposes a substrate to a pattern through a projection optical system, the apparatus comprising a substrate stage which holds and moves the substrate and a supply unit, which has a supply nozzle and supplies a liquid to a surface of the substrate, an opening of the supply nozzle being arranged at a side of the projection optical system so as to oppose the substrate, and the supply unit supplying the liquid in accordance with movement of the substrate by the substrate stage.
According to the second aspect of the present invention, there is provided an exposure apparatus which exposes a substrate to a pattern through a projection optical system, the apparatus comprising a substrate stage, which holds and moves the substrate, a movable flat plate, a supply unit, which supplies a liquid to at least one of a portion between a final surface of the projection optical system and the substrate and a portion between the final surface and the flat plate, and a recovery unit which recovers the liquid from at least one of a portion between the final surface and the substrate and a portion between the final surface and the flat plate.
According to the third aspect of the present invention, there is provided an exposure apparatus, which exposes a substrate to a pattern through a projection optical system, the apparatus comprising a substrate stage, which holds and moves the substrate, an opposing member, which extends from an end portion of a final surface of the projection optical system and has a surface opposing the substrate, and a supply unit, which supplies a liquid to a surface of the substrate through an outlet port formed in the opposing surface.
According to the fourth aspect of the present invention, there is provided an exposure apparatus which exposes a substrate to a pattern through a projection optical system, the apparatus comprising a substrate stage, which holds and moves the substrate, a supply unit, which supplies a liquid to a space between a final surface of the projection optical system and the substrate through a supply port, and an ejecting portion, which ejects a gas toward the substrate through an ejecting port formed outside the supply port with respect to the final surface.
According to the fifth aspect of the present invention, there is provided an exposure method of exposing a substrate to a pattern through a projection optical system, the method comprising steps of moving the substrate by a substrate stage, and supplying a liquid to a surface of the substrate through a supply nozzle, an opening of the supply nozzle being arranged at a side of the projection optical system so as to oppose the substrate, and in the supply step, the liquid being supplied in accordance with movement of the substrate by a substrate stage.
According to the sixth aspect of the present invention, there is provided an exposure method of exposing a substrate to a pattern through a projection optical system, the method comprising steps of moving the substrate by a substrate stage, moving a movable flat plate, supplying a liquid to at least one of a portion between a final surface of the projection optical system and the substrate and a portion between the final surface and the flat plate, and recovering the liquid from at least one of a portion between the final surface and the substrate and a portion between the final surface and the flat plate.
According to the seventh aspect of the present invention, there is provided a device manufacturing method comprising a step of exposing a substrate to a pattern using any one of the above exposure apparatuses of the present invention.
Other features and advantages of the present invention will be apparent from the following description taken in conjunction with the accompanying drawings, in which like reference characters designate the same or similar parts throughout the figures thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
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.
FIG. 1 is a view schematically showing the arrangement of a preferred embodiment of the present invention;
FIGS. 2A to 2G are sectional views schematically showing steps of filling with a liquid the gap between a projection optical system and a wafer;
FIG. 3 is a view showing the first arrangement example of a liquid supply nozzle and liquid recovery nozzle in an exposure apparatus according to the preferred embodiment of the present invention;
FIG. 4 is a view showing the second arrangement example of the liquid supply nozzle and liquid recovery nozzle in the exposure apparatus according to the preferred embodiment of the present invention;
FIG. 5 is a view showing the third arrangement example of the liquid supply nozzle and liquid recovery nozzle in the exposure apparatus according to the preferred embodiment of the present invention;
FIG. 6 is a view showing the fourth arrangement example of the liquid supply nozzle and liquid recovery nozzle in the exposure apparatus according to the preferred embodiment of the present invention;
FIG. 7 is a view showing the fifth arrangement example of the liquid supply nozzle and liquid recovery nozzle in the exposure apparatus according to the preferred embodiment of the present invention;
FIG. 8 is a view schematically showing part of the arrangement of another preferred embodiment of the present invention;
FIGS. 9A to 9D are sectional views showing steps of feeding a flat plate below a projection optical system in an exposure apparatus according to the embodiment shown in FIG. 8 ;
FIGS. 10A to 10D are sectional views showing another step of feeding the flat plate below the projection system in the exposure apparatus according to the embodiment shown in FIG. 8 ;
FIGS. 11A to 11D are sectional views showing a step of generating a liquid film below the projection optical system in the exposure apparatus according to the embodiment shown in FIG. 8 ;
FIGS. 12A to 12C are sectional views showing another step of generating a liquid film below the projection optical system in the exposure apparatus according to the embodiment shown in FIG. 8 ;
FIG. 13 is a view showing the sixth arrangement example of the liquid supply nozzle and liquid recovery nozzle in the exposure apparatus according to the embodiment shown in FIG. 8 ;
FIG. 14 is a view showing the seventh arrangement example of the liquid supply nozzle and liquid recovery nozzle in the exposure apparatus according to the embodiment shown in FIG. 8 ;
FIG. 15 is a view showing an arrangement example of a nozzle unit (nozzle unit comprising a plurality of nozzles) in the exposure apparatus according to the embodiment shown in FIG. 8 ;
FIG. 16 is a view showing an application of the nozzle unit shown in FIG. 15 ; and
FIG. 17 is a flowchart showing the whole manufacturing process of a semiconductor device.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
An exposure apparatus according to the present invention is useful to, e.g., all exposure methods and exposure apparatuses that use ultraviolet light as exposure light and use immersion in which the gap between a projection optical system and a substrate (e.g., a wafer) is filled with a liquid. These exposure apparatuses can include, e.g., one which projects and transfers a pattern on a master onto a substrate while the substrate is in a stationary state and one which performs scanning exposure for a substrate to a pattern on a master using slit light while synchronously scanning the substrate and master.
A preferred embodiment of the present invention will be illustrated below. FIG. 1 is a view schematically showing the arrangement of the preferred embodiment of the present invention. In FIG. 1 , light emitted from an exposure light source (not shown) such as an ArF excimer laser or F 2 laser is supplied to an illumination optical system 2 . The illumination optical system 2 uses the light supplied from the exposure light source to illuminate part of a reticle (master) 1 with slit light (light having a sectional shape as if it passed through a slit). While illuminating the reticle 1 with the slit light, a reticle stage (master stage) 3 holding the reticle and a wafer stage (substrate stage) 10 holding a wafer (substrate) 9 perform scanning movement in synchronism with each other. Through this synchronous scanning, an image of the entire pattern on the reticle 1 is continuously formed on the wafer 9 through a projection optical system 4 to expose to light a resist applied to the surface of the wafer 9 .
The two-dimensional positions of the reticle stage 3 and wafer stage 10 are measured in real time by a reference mirror 11 and distance measurement laser interferometer 12 , respectively. A stage control apparatus 13 performs alignment and synchronous control for the reticle 1 (reticle stage 3 ) and wafer 9 (wafer stage 10 ) on the basis of the measurement values from the reference mirror 11 and distance measurement laser interferometer 12 . The wafer stage 10 incorporates a driving unit which adjusts, changes, or controls the vertical position, rotational direction, and tilt of the wafer 9 . In exposure, the driving unit controls the wafer stage 10 such that an exposure region on the wafer 9 precisely coincides with the focal plane of the projection optical system 4 . The position (vertical position and tilt) of the upper surface of the wafer 9 is measured by an optical focus sensor (not shown) and is supplied to the stage control apparatus 13 .
An exposure apparatus main body is placed in an environment chamber (not shown), and the environment of the exposure apparatus main body is kept at a predetermined temperature. Temperature-controlled air for air conditioning is separately supplied to a space surrounding the reticle stage 3 , wafer stage 10 , and distance measurement laser interferometer 12 , and a space surrounding the projection optical system 4 , thereby maintaining the ambient temperature at higher precision.
In this embodiment, immersion in which the space or gap between the projection optical system 4 and the wafer 9 is filled with a liquid is implemented by a liquid supply nozzle 5 arranged above the wafer 9 and in the vicinity of the projection optical system 4 and a liquid recovery nozzle 6 opposing the liquid supply nozzle 5 through the projection optical system 4 .
Immersion to be performed in this embodiment will be described below in detail. The liquid supply nozzle 5 is arranged upstream in a direction in which the wafer 9 is scanned during exposure and in the vicinity of the projection optical system 4 . For example, if the wafer is to be moved from right to left, i.e., leftward (second direction), the upstream of the scanning direction is on the right (first direction). More specifically, if the scanning direction (second direction) is indicated by an arrow, the side of the starting point of the arrow (first direction) is the upstream. The liquid recovery nozzle 6 opposes the liquid supply nozzle 5 (i.e., downstream in the scanning direction) through the projection optical system 4 .
The liquid supply nozzle 5 is connected to a liquid supply unit 7 through a supply pipe 16 . Similarly, the liquid recovery nozzle 6 is connected to a liquid recovery unit 8 through a recovery pipe 17 . The liquid supply unit 7 can include a tank, which stores a liquid, a pressure feed unit, which feeds the liquid, and a flow controller, which controls the supply flow rate of the liquid. The liquid supply unit 7 preferably further includes a temperature controller for controlling the supply temperature of the liquid. The liquid recovery unit 8 can include, e.g., a tank, which temporarily stores a recovered liquid, a suction unit, which sucks the liquid, and a flow controller for controlling the recovery flow rate of the liquid. An immersion controller 18 receives information such as the current position, velocity, acceleration, target position, and moving direction of the wafer stage 10 from the stage control apparatus 13 and gives instructions to start or stop immersion, control the flow rate, and the like, to the liquid supply unit 7 and liquid recovery unit 8 , on the basis of this information.
As an immersion liquid, one which absorbs little exposure light is selected. The immersion liquid desirably has a refractive index almost equal to that of a dioptric element made of, e.g., quartz or fluorite. More specifically, examples of the immersion liquid include pure water, functional water, a fluorinated solution (e.g., fluorocarbon), and the like. A dissolved gas is preferably well removed from the immersion liquid using a degasifier. This aims at suppressing generation of air bubbles and immediately absorbing any generated air bubbles in the liquid. For example, if nitrogen and oxygen, which are contained in a large quantity in the environmental gas, are removed from the liquid by 80% or more of the maximum permissible gas content of the liquid, generation of air bubbles can sufficiently be suppressed. The exposure apparatus may be provided with a degasifier (not shown) and may supply a liquid to the liquid supply unit 7 while removing a gas dissolved in the liquid. As the degasifier, e.g., a vacuum degasifier is preferably used. This vacuum degasifier supplies a liquid to one side of a gas-permeable film, evacuates the other side to a vacuum, and traps a gas dissolved in the liquid into the vacuum through the film.
A step of filling a liquid between the projection optical system 4 and the wafer 9 will be described with reference to FIGS. 2A to 2G .
While the wafer 9 is in a stationary state or is moving, the liquid supply nozzle 5 supplies a liquid f onto the water 9 at, e.g., a constant flow rate to bring the liquid into intimate contact with the lower surface of the liquid supply nozzle 5 and the upper surface of the wafer 9 . With this operation, a satisfactory liquid film is formed ( FIG. 2A ).
The wafer 9 starts moving or further moves while continuously supplying the liquid from the liquid supply nozzle 5 . The movement of the wafer is used to guide the liquid film below the projection optical system 4 without breaking the liquid film (formed in FIG. 2A ) ( FIGS. 2B and 2C ).
When the wafer 9 further moves to reach an exposure start position, scanning exposure using slit light starts ( FIG. 2D ). During the slit exposure, the liquid supply nozzle 5 continuously supplies the liquid, as described with reference to FIG. 2C , and the liquid recovery nozzle 6 starts recovering the liquid flowing from the downstream side (on the left in FIGS. 2A to 2G ) of a scanning direction S with respect to the projection optical system 4 . With this operation, a space between the wafer 9 and the projection optical system 4 is stably filled with the liquid ( FIG. 2D ).
When the wafer 9 further moves to reach an exposure end position, the exposure using the slit light ends ( FIG. 2E ). Upon completion of the exposure using the slit light, the liquid supply nozzle 5 stops supplying the liquid ( FIG. 2E ). The liquid recovery nozzle 6 recovers the liquid left on the wafer 9 while moving the wafer 9 in the scanning direction S ( FIGS. 2F and 2G ).
If the liquid is continuously supplied onto the surface of the wafer 9 while moving the wafer 9 such that a liquid film expands along with the movement of the wafer 9 , as described above, the gap between the final surface of the projection optical system 4 and the wafer can be filled with a continuous liquid film. This method can more reliably form a liquid film in the gap between the projection optical system 4 and the wafer 9 even when the gap is small and can more greatly reduce air bubbles in the liquid film, than a method disclosed in WO99/49504 of directing a nozzle toward the gap between the projection optical system 4 and the wafer 9 and supplying a liquid toward the gap. Also, according to this method, the liquid film moves at a lower velocity than the wafer and, thus, can reliably be recovered through the liquid recovery nozzle 6 . Thus, outward splashes of the liquid can effectively be prevented.
A sequence for supplying and recovering a liquid, as described above, may be performed for each exposure shot region (each transfer of a reticle image). Alternatively, the sequence may be performed for all or some of the exposure shot regions on the wafer. In the latter case, supply and recovery of a liquid may be or may not be performed during stepping of the wafer between the exposure shot regions.
The above-mentioned immersion can be applied to an exposure apparatus which exposes a wafer while the wafer is in a stationary state (e.g., a so-called stepper). In this case, when, e.g., the wafer is stepped between the exposure shot regions, supply and recovery of a liquid is preferably controlled so as to expand a liquid film between an exposure shot region to be exposed next and the lower surface of the projection optical system 4 .
Preferred examples of the detailed structures and layout of the liquid supply nozzle 5 and liquid recovery nozzle 6 will be described with reference to FIGS. 3 to 7 .
FIG. 3 is a plan view as seen from above, obtained by cutting the exposure apparatus in FIG. 1 above the wafer 9 . The liquid supply nozzle 5 is arranged upstream (in the −X direction as seen from the projection optical system 4 ), in a moving direction S (in the +X direction as seen from the projection optical system 4 ) of the wafer 9 , of a final surface 4 s of the projection optical system 4 while the liquid recovery nozzle 6 is arranged downstream (in the +X direction as seen from the projection optical system 4 ). When the exposure apparatus is a scanner (scanning exposure apparatus), the moving direction of the wafer 9 is desirably the same as that of the scanning direction of the wafer in exposure in order to stably form a liquid film.
The liquid supply nozzle 5 is preferably arranged such that its lower surface (lower end) is flush with or higher than the final surface (lower surface 4 s ) of the projection optical system 4 . With this arrangement, a liquid can move together with the wafer in intimate contact with the final surface of the projection optical system 4 while eliminating an air layer. This prevents inclusion of air bubbles in a liquid film.
The liquid recovery nozzle 6 is preferably arranged such that its lower surface (lower end) is flush with or higher than the final surface (lower surface) 4 s of the projection optical system 4 . With this arrangement, a liquid on the wafer can efficiently be recovered while preventing a failure to recover the liquid (incomplete recovery).
A total length L 1 of an outlet port through which the liquid supply nozzle 5 discharges a liquid is preferably equal to or larger than a length Le of a region through which exposure light beams pass and is more preferably equal to or larger than the width of the final surface 4 s of the projection optical system 4 . A length L 2 of the liquid recovery nozzle 6 is preferably equal to or larger than the length L 1 of the liquid discharge port of the liquid supply nozzle 5 and is more preferably equal to or larger than the width of the final surface 4 s.
A flow rate V of a liquid to be supplied from the liquid supply nozzle 5 to a space (immersion space) between the wafer 9 and the lower surface of the projection optical system 4 is desirably determined in accordance with equation (1):
V≧L 1 ·d·v (1)
where d is a thickness of the space between the wafer and the final surface (lower surface) of the projection optical system 4 , and v is a moving velocity of the wafer in immersion and is a scanning velocity of the wafer in scanning exposure.
Letting μ be a mean velocity of a liquid, to be supplied from the liquid supply nozzle 5 to the immersion space, at the liquid discharge port of the liquid supply nozzle 5 , the flow rate V of the liquid is given by equation (2):
V=L 1 ·w·μ (2)
where w is a width of the liquid discharge port. Equation (3) is derived from equations (1) and (2):
μ≧ d·v/w. (3)
More generally, the flow rate of the liquid to be supplied is preferably determined such that the mean velocity at the liquid discharge port of the liquid supply nozzle 5 (i.e., the supply flow rate per unit area of the discharge port) is equal to or larger than the quotient obtained by dividing, by the width w of the discharge port, the product of the thickness d of the gap between the final surface 4 s and the wafer 9 and the moving velocity v of the wafer stage 10 . In the strict definition, w is the minimum of the width of the liquid discharge port along the moving direction of the wafer 9 in the corresponding liquid supply nozzle 5 .
To start exposure from an end portion of the wafer, a liquid film needs to be sufficiently grown below the final surface (lower surface) 4 s of the projection optical system 4 before the end portion of the wafer reaches an exposure region (region to be irradiated with exposure light). In the arrangement example shown in FIG. 3 , a flush plate (flat plate) 19 almost flush with the wafer 9 is provided outside the wafer 9 . This makes it possible to form a liquid film outside the wafer 9 .
FIG. 4 is a view showing the second arrangement example of the structures and layout of the liquid supply nozzle 5 and liquid recovery nozzle 6 . The second arrangement example shown in FIG. 4 is different from the first arrangement example shown in FIG. 3 in that the ports of the liquid supply nozzle 5 and liquid recovery nozzle 6 are arranged within the surfaces (opposing surface opposing the wafer stage or wafer) of contiguous members 20 a and 20 b.
The bottom surfaces (opposing surfaces) of the contiguous members 20 a and 20 b are almost flush with the final surface 4 s . The edge of the final surface 4 s is so arranged as to come into intimate contact with the outer surface of the lens barrel of the projection optical system 4 . With this arrangement, an interval between the wafer 9 and the bottom surface of the liquid supply nozzle 5 , that between the wafer 9 and the bottom surface of the liquid recovery nozzle 6 , and that between the wafer 9 and the final surface 4 s can be made almost equal to each other, and the bottom surface of the liquid supply nozzle 5 , the final surface 4 s , and the bottom surface of the liquid recovery nozzle 6 , can constitute contiguous surfaces.
This arrangement, in which the liquid supply nozzle 5 and liquid recovery nozzle 6 are arranged within planes contiguous to the final surface 4 s , has the following advantage. More specifically, a liquid supplied from the liquid supply nozzle 5 comes into intimate contact with the wafer 9 and the bottom surface of the contiguous member 20 a , in which the liquid supply nozzle 5 is formed, to form a liquid film. This liquid film, together with the wafer 9 , moves toward the final surface 4 s , which is contiguous to the bottom surface of the contiguous member 20 a . The liquid film can smoothly advance to the final surface 4 s of the projection optical system 4 and then to the bottom surface of the contiguous member 20 b . In this manner, the final surface 4 s and the members 20 a and 20 b contiguous to the final surface 4 s make it possible to fill the entire gap between them and the wafer 9 with a liquid.
Since a liquid film always moves together with the wafer 9 while its upper and lower surfaces are in intimate contact with planes, contact of the liquid film with the environment (gas) is substantially limited to the side surfaces of the liquid film, and thus, the contact area of the liquid film with the gas is small. The liquid film flows through almost a constant gap and hardly changes in velocity. For this reason, the flow of the liquid film hardly disorders, and air bubbles are unlikely to be generated in the liquid film. Also, this reduces dissolution of a gas in a liquid and can suppress generation of micro-bubbles in the liquid film due to a change in temperature or a local change in pressure.
The contiguous members 20 a and 20 b may be like a thin plate or block, or may have any other shape as far as their bottom surfaces are contiguous to the final surface (lower surface) 4 s of the projection optical system 4 . The contiguous members 20 a and 20 b may be formed as portions integrated into the bottom surfaces of the nozzles 5 and 6 and/or the bottom surface of the lens barrel of the projection optical system 4 .
FIG. 5 is a view showing the third arrangement example of the structures and layout of the liquid supply nozzle 5 and liquid recovery nozzle 6 . The third arrangement example shown in FIG. 5 is different from the second arrangement example shown in FIG. 4 in that the liquid supply nozzles 5 ( 5 a and 5 b ) are arranged on both sides, respectively, of the final surface 4 s , and the liquid recovery nozzles 6 ( 6 a and 6 b ) are arranged on both sides, respectively, of the final surface 4 s.
The liquid supply nozzles 5 a and 5 b are arranged relatively nearer to the final surface 4 s of the projection optical system 4 so as to sandwich the projection optical system 4 . On the other hand, the liquid recovery nozzles 6 a and 6 b are arranged relatively farther from the final surface 4 s of the projection optical system 4 , i.e., outside the liquid supply nozzles 5 a and 5 b.
While the wafer 9 moves in the +X direction indicated by an arrow shown in FIG. 5 , the liquid supply nozzle 5 a supplies a liquid to the gap between the wafer 9 and the final surface 4 s , and the liquid supply nozzle 5 b does not supply the liquid. At this time, the liquid recovery nozzle 6 b can recover most of the liquid. However, the liquid may flow in a direction opposite to the liquid recovery nozzle 6 b , depending on the flow rate of the liquid to be supplied from the liquid supply nozzle 5 a . Under the circumstances, in addition to the liquid recovery nozzle 6 b , the liquid recovery nozzle 6 a is operated to recover the liquid flowing in the opposite direction. This can prevent splashes or spills of the liquid. In consideration of this effect, preferably, liquid recovery nozzles are arranged so as to surround the perimeter of the final surface 4 s and are operated in supplying a liquid from the liquid supply nozzles.
While the wafer 9 moves in the −X direction indicated by an arrow shown in FIG. 5 , the liquid supply nozzle 5 b supplies a liquid, and the liquid supply nozzle 5 a does not supply the liquid, contrary to the above-mentioned case. In this manner, the gap between the wafer 9 and the final surface 4 s can always be filled with the liquid, regardless of the moving direction of the wafer. By switching the supply of the liquid between both the nozzles 5 a and 5 b , even when the moving direction of the wafer is reversed, the gap between the wafer 9 and the final surface 4 s can be filled with the liquid without breaking the liquid film (without dividing the liquid film).
The shape of the final surface 4 s need not be circular. For example, if the final surface 4 s is oval, and portions facing the nozzles are linear, as shown in FIG. 5 , the liquid supply nozzles 5 a and 5 b and liquid recovery nozzles 6 a and 6 b can be brought near to the optical path of exposure light beams. This can reduce the time required to fill the gap with the liquid and the moving distance of the wafer. In the case of a scanner, exposure light beams are slit-shaped on the surface of the wafer, and light beams, each having a sectional shape, which is short in the scanning direction and is long in a direction perpendicular to the scanning direction, are used in the final surface 4 s , which is close to the wafer surface. The final surface of the projection optical system 4 can be formed into a shape, which is short in the scanning direction, such as an oval, in accordance with the section shape of the light beams. The shape of the final surface of the projection optical system is not limited to an oval, and the final surface can have various shapes, such as a rectangle, an arc, and the like.
FIG. 6 is a view showing the fourth arrangement example of the structures and layout of the liquid supply and liquid recovery nozzles. In the fourth arrangement example shown in FIG. 6 , liquid supply nozzles 5 a to 5 d are provided on all sides surrounding the final surface 4 s , and liquid recovery nozzles 6 a to 6 d are further provided so as to surround the liquid supply nozzles 5 a to 5 d . When the wafer moves in the +X direction indicated by an arrow shown in FIG. 6 , the liquid supply nozzle 5 a arranged upstream in the moving direction of the wafer supplies a liquid. When the wafer moves in the −X direction indicated by an arrow shown in FIG. 6 , the liquid supply nozzle 5 B supplies this liquid. Also, when the wafer moves in the +Y direction indicated by an arrow, a liquid supply nozzle 5 c supplies the liquid. When the wafer moves in the −Y direction indicated by an arrow, a liquid supply nozzle 5 d supplies the liquid.
Since most of the liquid is recovered by the liquid recovery nozzles arranged downstream in the moving direction of the wafer, only the downstream recovery nozzles may be made to operate. However, simultaneous operation of all four of the liquid recovery nozzles 6 a to 6 d at least while they are supplying the liquid in preparation for unexpected events, such as malfunctioning, can more reliably prevent splashes or spills of the liquid. Instead of providing a plurality of liquid recovery nozzles, one liquid recovery nozzle may be provided around the sides of the final surface 4 s so as to surround the sides. The flow rate of the liquid to be supplied from the liquid recovery nozzles 6 a to 6 d is preferably determined in accordance with equation (3). With the above-mentioned arrangement, the moving direction of the wafer is not limited to the X or Y direction, and even if the wafer moves diagonally, the liquid film can be maintained.
As described above, a plurality of liquid supply nozzles are so arranged as to surround the final surface 4 s , and one or more liquid supply nozzles for use in supply are switched between the liquid supply nozzles such that ones arranged upstream in the moving direction (the opposite side of the moving direction as seen from the projection optical system) supply the liquid in wafer movement. With this operation, the gap between the final surface 4 s and the wafer 9 can always be supplied with the liquid regardless of the moving direction of the wafer. As a result, the gap between the wafer 9 and the final surface 4 s can be filled with the liquid without breaking the liquid film not only during scanning exposure, but also during stepping within the surface of the wafer or in changing the moving direction of the wafer. This makes it possible to, in one wafer, fill the gap between the final surface 4 s and the wafer 9 with the liquid without breaking the liquid film from the start of the exposure to when exposure of the entire wafer is completed. Consequently, the need for forming a liquid film for every shot is eliminated, and the productivity of the exposure apparatus greatly increases.
FIG. 7 is a view showing the fifth arrangement example of the structures and layout of the liquid supply nozzles and liquid recovery nozzles. In this arrangement example, the liquid supply nozzles 5 a to 5 d and liquid supply nozzles 5 e to 5 h , and the liquid recovery nozzles 6 a to 6 d and liquid recovery nozzles 6 e to 6 h are so arranged on circumferences so as to surround the perimeter of the final surface 4 s . The liquid supply nozzles are arranged inside the liquid recovery nozzles. The nozzles on the circumferences make it possible to fill the gap between the final surface 4 s and the wafer with the liquid by supplying the liquid from one arranged almost upstream in the moving direction and recovering the liquid by at least one arranged downstream of the moving direction, even when the wafer stage 10 moves diagonally.
For example, when the wafer moves at an angle of 45° from the +X and +Y directions, as indicated by an arrow shown in FIG. 7 , the nozzles are preferably controlled such that at least the liquid supply nozzles 5 b and 5 c supply the liquid, while at least the liquid recovery nozzles 6 f and 6 g recover the liquid. The layout of the nozzles on the circumferences makes it possible to more flexibly form a corresponding liquid film in various moving directions of the wafer. FIG. 7 shows the plurality of divided liquid recovery nozzles. However, simultaneous operation of all the liquid recovery nozzles 6 a to 6 h at least while they are supplying the liquid in preparation for unexpected events, such as malfunctioning, can more reliably prevent splashes or spills of the liquid, as described in the fourth arrangement example. Instead of providing a plurality of liquid recovery nozzles, only one liquid recovery nozzle may be provided around the perimeter of the final surface 4 s so as to surround the perimeter.
When the gap between the wafer and the final surface 4 s is not filled with the liquid or when there is still gas in the gap due to incomplete filling with the liquid, the liquid is preferably supplied from upstream in the moving direction of the wafer, as has been described above. On the other hand, after the gap between the wafer 9 and the final surface 4 s is completely filled with the liquid, all liquid supply nozzles may supply the liquid regardless of the moving direction of the wafer. In this case, the flow rate of the liquid to be supplied and that of the liquid to be recovered increase, and the running cost increases. On the other hand, supply nozzle switching need not be performed frequently, and the time required for switching is saved, thereby increasing the productivity of the exposure apparatus. Also, the need for a driving unit, which switches between the supply nozzles, is eliminated, and the size of each liquid supply unit can be reduced. Control of liquid supply is not limited to the arrangement example shown in FIG. 7 and can be applied to the nozzle arrangements shown in FIGS. 5 and 6 . In this case, as well, the same effect can be obtained.
In the arrangement example shown in FIG. 7 , the flow rate of the liquid supplied from the liquid supply nozzles may be determined by applying equation (3) to each liquid supply nozzle. For the sake of simplicity, the liquid can be supplied uniformly from all the liquid supply nozzles at the same flow rate. In the arrangement example shown in FIG. 7 , since the discharge ports of the liquid supply nozzles are arranged concentrically about the exposure light beams, the width of the liquid supply port is set to have a constant value w′ regardless of the moving direction of the wafer. A total flow rate V′ is preferably determined in accordance with equation (4):
V′≧π·D·d·v (4)
where π is the circular constant, D is the average diameter of the discharge ports, d is an interval between the wafer and the final surface, and v is the moving velocity of the wafer.
Another preferred embodiment of the present invention will be described with reference to FIGS. 8 and 9A to 9 D. FIG. 8 is a plan view of a wafer stage 10 as seen from above the nozzles arranged on a projection optical system final surface 4 s and its surroundings. The discharge ports of a liquid supply nozzle 5 and liquid recovery nozzle 6 are so arranged as to oppose a wafer 9 , and they should be drawn by hidden lines (broken lines) in this plan view as seen from above, according to proper drawings. For the sake of illustrative simplicity, the discharge ports are drawn using solid lines.
A flat plate 21 is provided adjacent to the wafer 9 chuck on the wafer stage 10 . The flat plate 21 is so arranged as to be flush with the upper surface of the wafer 9 , which is fixed on the wafer stage 10 by vacuum chucking, or the like. A wafer transport apparatus (not shown) is provided to recover/mount the wafer 9 from/onto the wafer stage 10 when the flat plate 21 is located immediately below the final surface 4 s.
The steps in this embodiment will be described with reference to FIGS. 9A to 9D . FIGS. 9A to 9D show operation of the units in order of the steps, using the cross-sectional view of the main part of FIG. 8 .
During exposure, a liquid is supplied from the liquid supply nozzle 5 as needed and is recovered by the liquid recovery nozzle 6 . In the meantime, the gap between the wafer 9 and the final surface 4 s is kept in a state in which the gap is always filled with the liquid ( FIG. 9A ). After an exposure sequence for one wafer 9 ends, the wafer stage 10 is moved such that the flat plate 21 , which is adjacent to the wafer 9 , is located immediately below the final surface 4 s ( FIG. 9B ). In moving the wafer stage 10 , the liquid supply nozzle 5 continuously supplies the liquid while the liquid recovery nozzle 6 continuously recovers the liquid. With this operation, even when the flat plate 21 is located below the final surface 4 s , a space below the final surface 4 s is always filled with the liquid. While keeping this state, the exposed wafer 9 , which is chucked and fixed on the wafer stage 10 , is recovered from the wafer stage 10 to a wafer storage unit (not shown). In addition, a new wafer 9 ′ is mounted on the wafer stage 10 and is chucked and fixed on the wafer stage 10 ( FIG. 9C ).
The wafer stage 10 is moved while the liquid supply nozzle 5 continuously supplies the liquid, and the liquid recovery nozzle 6 continuously recovers the liquid. The wafer 9 ′ is fed to immediately below the final surface 4 s while filling the space below the final surface 4 s with the liquid ( FIG. 9D ).
This movement of the flat plate 21 to an exposure position while continuously supplying and recovering the liquid even after the exposure makes it possible to recover most of the liquid on the wafer. Accordingly, wafer replacement can smoothly be performed without any special liquid recovery operation, and the productivity of exposure apparatuses can be increased. Since the final surface 4 s is always filled with the liquid regardless of whether the wafer replacement is being performed, no impurity contained in the ambient atmosphere directly comes into contact with the final surface 4 s . Additionally, the contact area between the liquid and the air is minimized, and thus, the amount of impurities to be absorbed in the liquid can be minimized. Thus, any cloud due to the impurities can be suppressed in the final surface 4 s.
When the liquid is recovered every time wafer replacement is performed, a thin liquid film is temporarily attached to the surface of the final surface 4 s . If the liquid is pure water, or the like, inorganic components or hydrophilic organic components contained in the environment are likely to be absorbed in the film of pure water. After the pure water evaporates, the inorganic components or organic components are highly likely to remain on the surface of the projection optical system, thereby causing a cloud.
As shown in FIGS. 9B and 9C , during replacement of wafers on the wafer stage 10 , a liquid film is maintained between the final surface 4 s and the flat plate 21 . Immediately before this state, the liquid film had come into contact with the surface of a photosensitive agent applied to the wafer and had received exposure light. When the photosensitive agent is exposed, components contained in the photosensitive agent are released in any event as gas-like substances, and these gas-like substances may be dissolved in the liquid film, which is in contact with the upper surface of the photosensitive agent.
Immediately after the exposure, the gas-like substances are dissolved in the liquid film, and the liquid film is contaminated. The liquid film is preferably replaced with a new one before the start of the next exposure. Otherwise, the dissolved impurities change the transmittance of the liquid film and adversely affect exposure amount control. Degradation in productivity of exposure apparatuses, such as variations in line width, may occur. Furthermore, the dissolved impurities may be supersaturated and may appear as air bubbles, thereby causing poor imaging. The impurities dissolved in the liquid film cause a chemical reaction by exposure light, and may cause clouds in the final surface. Under the circumstances, these problems and solutions to them will be considered.
While the liquid supply nozzle 5 continuously supplies a new liquid, and the liquid recovery nozzle 6 continuously recovers the liquid, the liquid film will be replaced with the new liquid even when the replacement rate is low. Accordingly, in some cases, only supply and recovery by the nozzles 5 and 6 may increase the purity of the liquid film to a level sufficient enough for the next exposure on the wafer 9 or flat plate 21 . If the flow rate of the supply or recovery is increased immediately after exposure and is returned to the original flow rate immediately before exposure, the purity of the liquid film can further be increased. In this case, if the wafer 9 and flat plate 21 are moved along with a change in flow rate, and the moving velocities of the wafer 9 and flat plate 21 are changed along with the change in flow rate, the replacement rate of the liquid rate increases. Supplying and recovering the liquid while reciprocating or rotating the wafer 9 or flat plate 21 is more preferable because liquid films can be replaced continuously.
While the liquid supply nozzle 5 continuously supplies a new liquid, and the liquid recovery nozzle 6 continuously recovers the liquid, the liquid film will be replaced with new liquid even when the replacement rate is low. Accordingly, in some cases, only supply and recovery by the nozzles 5 and 6 may increase the purity of the liquid film to a level sufficient enough for the next exposure on the wafer 9 or flat plate 21 . If the flow rate of the supply or recovery is increased immediately after exposure and is returned to the original flow rate immediately before exposure, the purity of the liquid film can further be increased. In this case, if the wafer 9 and flat plate 21 are moved along with a change in flow rate, and the moving velocities of the wafer 9 and flat plate 21 are changed along with the change in flow rate, the replacement rate of the liquid rate increases. Supplying and recovering the liquid while reciprocating or rotating the wafer 9 or flat plate 21 is more preferable because liquid films can be replaced continuously.
This increase or decrease in supply flow rate and recovery flow rate may be performed for every shot region or every wafer. The interval between executions or timings of execution may be changed as needed. Even if the exposure process is not performed, outgassing can occur depending on the material for the photosensitive agent to be used. In some cases, just contact of a liquid film with the photosensitive agent can cause contamination to develop. In other cases, outgassing may occur in a large amount with respect to the necessary exposure amount. Hence, a liquid film may be contaminated more than expected.
Under the circumstances, as another method of more actively replacing a liquid film below the final surface of the projection system with a new liquid, a suction port 22 may be provided at an appropriate position such as the center of the flat plate 21 , as shown in FIGS. 10A to 10D . Suction units (not shown), such as a suction pump and cylinder, are connected to the suction port 22 to suck a gas or liquid. More specifically, as shown in FIGS. 10A to 10D , a liquid is recovered from the suction port 22 while the flat plate 21 is fed below the final surface 4 s . At the same time, the flow rate to be supplied from the liquid supply nozzle 5 is increased by at least the same amount as the flow rate to be sucked from the suction port 22 . With this operation, most of the liquid film below the final surface 4 s flows not only externally in the radius direction (toward the liquid recovery nozzle 6 ), but toward the suction port 22 at the center. Even when the flat plate 21 is in a stationary state, the liquid film can always continuously be replaced with a new liquid ( FIGS. 10B and 10C ).
With the above-mentioned arrangement, the replacement rate of the liquid below the final surface 4 s drastically increases. Liquid replacement is performed not only on a photosensitive agent susceptible to contamination, but on the flat plate 21 , which can employ a material that is resistant to chemical contamination and can maintain the cleanliness with ease. For this reason, a gap below the final surface 4 s can be filled with a liquid of high purity. Thus, influences, such as a cloud of impurities in the outer air or impurity gas components generated from the surface of the photosensitive agent onto the final surface 4 s , can effectively be suppressed.
Liquid film replacement, as shown in FIGS. 9A to 9D and 10 A to 10 D, is not limited to wafer replacement. The liquid film replacement can be performed as needed, even during an exposure sequence of one wafer regularly or irregularly.
In the arrangement example shown in FIGS. 9A to 9D and 10 A to 10 D, the flat plate 21 is arranged on the wafer stage. When a wafer is transferred between the wafer stage and a wafer transport apparatus (not shown), the flat plate 21 is located immediately below the final surface 4 s . However, the flat plate 21 may be arranged to be located immediately below the final surface 4 s even when various operations necessary before and after exposure or various operations necessary for maintaining and managing the exposure apparatus, such as an alignment measurement step with an off-axis microscope (not shown), before exposure. If a plurality of flat plates 21 or a plurality of suction ports 22 need to be arranged at a plurality of wafer stage positions immediately below the final surface 4 s , the plurality of flat plates or a plurality of suction ports may be arranged on the wafer stage. Like the flush plate 19 shown in FIG. 3 , the flat play may be arranged so as to surround the wafer. Alternatively, a plurality of suction ports may be provided in the flat plate at the positions, each of which opposes the final surface during a respective one of the various operations.
In FIGS. 9A to 9D and 10 A to 10 D, the flat plate 21 is arranged on the wafer stage 10 . A dedicated driving unit (not shown) may be provided such that the flat plate 21 can move independently of the wafer stage 10 . In this case, the flat plate 21 should be driven so as not to form a large gap between the flat plate 21 and the wafer 9 , which is chucked and fixed on the wafer stage 10 . For example, when shifting from the state in FIG. 9A to that in FIG. 9B or when shifting from the state in FIG. 9C to that in FIG. 9D , the wafer stage 10 and flat plate 21 should be so driven as to move near the final surface 4 s while keeping a positional relationship to be adjacent to each other. At least while the gap between the wafer and the flat plate 21 passes immediately below the final surface, the flat plate 21 must be kept flush with the upper surface of the wafer.
After a liquid film is moved between the final surface and the flat plate 21 , the flat plate 21 maintains the position while the wafer stage 10 arbitrarily changes the position. With this operation, the flat plate 21 and wafer stage 10 can perform various steps. By providing a mechanism which moves the flat plate 21 independently of the wafer stage 10 , as described above, a space below the final surface 4 s can be filled with a liquid during a period when the wafer stage 10 is used for various operations other than exposure. Also, this mechanism eliminates the need for a plurality of flat plates or suction ports, and thus, the size of the exposure apparatus can be reduced.
A sensor 21 s , such as an illuminance uniformity sensor for measuring the illuminance distribution of exposure light or an absolute illumination meter for measuring the absolute illuminance, may be provided at an appropriate position of the flat plate 21 . In this case, illuminance uniformity and absolute illuminance can be measured while a space below the final surface 4 s is continuously filled with a liquid without temporarily recovering the liquid and in almost the same immersion state as during exposure. As described above, the flat plate preferably moves independently of the wafer stage in view of productivity. In the case of a scanning exposure apparatus, an illuminance uniformity sensor is preferably arranged on the wafer stage together with the flat plate because the cumulative illuminance uniformity during scanning can be measured.
Use of a function of sucking a gas or liquid from the suction port 22 makes it possible to generate an initial liquid film on the final surface 4 s more quickly. A method of generating an initial liquid film using the suction port 22 will be described with reference to FIGS. 11A to 11D .
First, the flat plate 21 is moved such that the suction port 22 is located immediately below almost the center of the liquid supply nozzle 5 , which is so arranged as to surround the perimeter of the final surface 4 s . In this state, a liquid is supplied onto the flat plate 21 from the entire perimeter of the liquid supply nozzle 5 ( FIG. 11A ).
The supplied liquid forms an annular liquid film f in accordance with the location of the liquid supply nozzle 5 between parallel planes (contiguous members) 20 , including the final surface 4 s and the flat plate 21 , while a gas g remains at the center. If the liquid is merely continuously supplied in this manner, the gas g is trapped by the liquid film f, and the gas g is not discharged outside. Accordingly, the space below the final surface 4 s cannot completely be filled with the liquid indefinitely.
Under the circumstances, the gas g is sucked through the suction port 22 while the liquid is annually supplied from the liquid supply nozzle 5 to the space below the final surface 4 s . This suction makes the pressure of the gas g more negative than the pressure of the outer environment. The difference in pressure causes a force to act on the liquid film formed around the perimeter of the gas g from the perimeter to the suction port 22 , and the liquid film starts spreading quickly toward the suction port 22 ( FIG. 11B ). The suction through the suction port 22 is continued. When the liquid starts to be sucked through the suction port 22 , the gap between the final surface 4 s and flat plate 21 is filled with a liquid film without the gas g ( FIG. 11C ).
The suction from the suction port 22 is stopped. While the suction is stopped, supply of a liquid from the liquid supply nozzle 5 may be stopped when the wafer stage 10 is stopped. However, when the liquid is in a stationary state, a gas constituting the environment or an impurity is always absorbed in the liquid. Then, the number of air bubbles or the concentration of an impurity increases, and trouble may occur. More specifically, air bubbles may not disappear and may remain until exposure, micro-bubbles may be generated by exposure, or the final surface may be clouded by the absorbed impurity. To prevent such trouble, it is preferable to continuously supply a liquid even while the wafer stage 10 is kept stopped and to recover the liquid by at least the liquid recovery nozzle 6 while the liquid is kept supplied.
During a period from that shown in FIG. 11A to that in FIG. 11C , the liquid recovery nozzle 6 may be stopped. To prevent the liquid from externally splashing due to vibrations, a sudden change in liquid supply amount, or the like, the liquid recovery nozzle 6 is preferably always operated.
Finally, the wafer stage 10 is moved such that the wafer 9 is located immediately below the final surface 4 s while continuously supplying and recovering the liquid ( FIG. 11D ).
As described above, if an annular liquid film grows toward the center, a liquid film free from air bubbles can be formed more quickly, and the productivity of the exposure apparatus can be increased. This method does not require movement of the stage. This method is suitable as a method of generating a large-area liquid film when a projection optical system with a larger numerical aperture is adopted.
With the suction port 22 , the liquid film can be recovered quickly. More specifically, when the liquid film is transferred between the final surface 4 s and the flat plate 21 , supply of the liquid from the liquid supply nozzle 5 is stopped, and the liquid is recovered from the suction port 22 . With this operation, most of the liquid film between the final surface 4 s and flat plate 21 can quickly be recovered. At this time, to more completely recover the liquid, the liquid may be sucked while moving the wafer stage 10 . With the recovery function of the liquid film, the liquid film can be recovered immediately. For this reason, maintenance and inspection operation of the apparatus, and a remedy operation against failure can quickly be performed without any delay.
The method of quickly generating an initial liquid film using the suction port 22 formed in the flat plate 21 has been described with reference to FIGS. 11A to 11D . Aside from this method, even when a liquid inlet port 23 is provided in the flat plate 21 instead of the suction port 22 , and a liquid is supplied from a liquid supply unit (not shown) through the liquid inlet port 23 , as shown in FIGS. 12A to 12C , the initial liquid film can quickly be generated to be described later. More specifically, in FIGS. 12A to 12D , the flat plate 21 is moved such that the liquid inlet port 23 is located immediately below almost the center of the liquid supply nozzle 5 , which is arranged so as to surround the perimeter of the final surface 4 s . In this state, the liquid is supplied onto the flat plate 21 through the liquid inlet port 23 . The supplied liquid forms a small liquid film between the final surface 4 s and the flat plate 21 , including the liquid inlet port 23 ( FIG. 12A ).
When the liquid is further supplied through the liquid inlet port 23 , the small liquid film f spreads radially ( FIG. 12B ), and the gap between the final surface 4 s and the flat plate 21 is supplied with the liquid.
The liquid is recovered as needed through the liquid recovery nozzle 6 . This prevents the liquid from leaking from the flat plate 21 or final surface 4 s ( FIG. 12C ).
Use of the liquid inlet port 23 also makes it possible to continuously fill the liquid film below the final surface 4 s without externally splashing or leaking the liquid while the flat plate 21 is in a stationary state, as described with reference to FIGS. 10A to 10D . More specifically, the liquid is supplied from the liquid inlet port 23 , and at the same time, the liquid is recovered through the liquid recovery nozzle 6 . At this time, supply of the liquid from the liquid supply nozzle 5 is preferably stopped.
With this operation, the space between the flat plate 21 and the final surface 4 s starts to be filled with a liquid from almost the center. This can make the contact area with the ambient gas smaller than a method of filling the liquid from the perimeter of the final surface 4 s using the suction port 22 . A gas dissolved in the initial liquid film or an impurity contained in the gas can be reduced. For this reason, more stable exposure/resolving performance can be obtained, and the effect of suppressing a cloud caused by an impurity can further be increased.
The suction port 22 shown in FIGS. 10A to 10D and 11 A to 11 D may be provided in the flat plate 21 , in addition to the liquid inlet port 23 . The liquid inlet port 23 may be used to generate an initial liquid film or perform liquid film replacement while the suction port 22 may be used to recover the liquid for replacing the liquid film portion with the ambient gas. A single opening portion can implement both of the functions of the liquid inlet port 23 and those of the suction port 22 . More specifically, a suction unit (not shown) and liquid supply unit (not shown) may communicate with an opening formed in the flat plate 21 through a switching valve, and the switching valve may be switched, thereby switching between the functions of the suction port 22 and those of the liquid inlet port 23 as needed. This can reduce the size of the flat plate 21 .
Use of the flat plate 21 , suction port 22 , and liquid inlet port 23 , described with reference to FIGS. 8 to 12C , is not limited to a combination with the liquid supply nozzle or liquid recovery nozzle described explicitly in this specification. For example, the flat plate 21 , suction port 22 , and liquid inlet port 23 can be used in combination with various liquid supply and recovery mechanisms, such as a liquid supply pipe and liquid recovery pipe disclosed in WO99/49504.
FIG. 13 is a perspective view showing the sixth arrangement of the structures and layout of a liquid supply nozzle and liquid recovery nozzle. The arrangement example shown in FIG. 13 is different from the arrangement example shown in FIG. 6 in that a peripheral portion (projection portion) 20 c is provided outside the perimeter of a liquid contact surface 20 a on which the liquid supply nozzles 5 are arranged and nearer to the wafer than the liquid contact surface 20 a , i.e., there is a step. The liquid recovery nozzles 6 are arranged annularly on the peripheral portion 20 c.
Since the peripheral portion 20 c is arranged outside the perimeter of the liquid contact surface 20 a on which a liquid film of the final surface 4 s is formed and nearer to the wafer than the liquid contact surface 20 a , a liquid is unlikely to escape outside the liquid contact surface 20 a . This can reduce the ability to recover a liquid through the liquid recovery nozzles 6 and can reduce the sizes of the liquid recovery nozzles 6 and a liquid recovery unit 8 . In the arrangement example shown in FIG. 13 , each liquid recovery nozzle 6 is arranged on the peripheral portion 20 c . However, the liquid recovery nozzles may be arranged on, e.g., the liquid contact surface 20 a or may be arranged on both of the liquid contact surface 20 a and peripheral portion 20 c to more reliably recover the liquid.
In the arrangement shown in FIG. 13 , the peripheral portion 20 c , which is raised from the liquid contact surface 20 a inside the peripheral portion 20 c , surrounds the perimeter of the final surface 4 s . For example, if the moving direction of the wafer is limited, the peripheral portion 20 c or stepped portion may be arranged only on the downstream side of the moving direction of the wafer. In this case, the length of the peripheral portion 20 c or stepped portion is desirably equal to or larger than that of the liquid recovery nozzle 6 .
Each of the ports of the liquid supply nozzles 5 and liquid recovery nozzles 6 may be arranged as a mere opening. However, to reduce nonuniformity of the liquid supply amount or recovery amount and prevent liquid dripping, a porous plate or porous member 5 a , 6 a with fine pores is preferably provided to each port. A porous member 5 a , 6 a formed by sintering a fibrous or particulate material or inorganic material is particularly preferable. As a material for the porous plate or member 5 a , 6 a (a material used for at least the surface), stainless, nickel, alumina, and quartz glass are preferably in view of their affinity for pure water, or a fluorinated solution used as an immersion medium.
FIG. 14 is a perspective view of the seventh arrangement example of the structures and layout of the liquid supply nozzle and liquid recovery nozzle. The arrangement example shown in FIG. 14 is different from the first to sixth arrangement examples in that an inert gas outlet portion 24 is provided at the outermost portion, which surrounds the final surface 4 s.
The inert gas outlet portion (outlet ring) 24 communicates with an inert gas supply unit (not shown) and is arranged to eject an inert gas toward the wafer or flat plate arranged below at almost a constant rate. While a liquid film is formed between the final surface 4 s and the wafer or flat plate, an inert gas is ejected from the inert gas outlet portion 24 . By applying a pressure to the liquid film with the inert gas from the perimeter side, a liquid constituting the liquid film can be prevented from externally splashing. This functions effectively, particularly when the wafer or flat plate moves. The supply of the inert gas presses the liquid film toward the center, and thus, the liquid film can be prevented from attaching to the surface of the wafer or the flat plate and remaining on it. The supply of the inert gas can also dry the surface of the wafer or flat plate. If the inert gas is used only to dry the wafer or flat plate, the pressure of the inert gas may be low.
To suppress nonuniformity in the ejecting rate between locations, a porous plate or porous member may be provided to the outlet port of the inert gas outlet portion 24 , like the liquid supply nozzle 5 . If the inert gas outlet portion 24 comprises a slit nozzle, which ejects an inert gas through a fine gap of about 0.1 mm, the consumption amount of the inert gas can be suppressed.
With the above-mentioned arrangement, a liquid can more reliably be prevented from remaining on the upper surface of the wafer or flat plate. This eliminates the need for a unit or operation to recover the remaining liquid and contributes to increasing the productivity of exposure apparatuses and preventing an increase in apparatus size. In addition, supply of an inert gas can reduce a period when the surface of a photosensitive agent applied to the upper surface of the wafer is kept wet and can immediately dry the surface of the photosensitive agent. The dependence on the wet stage, which influences a development step after exposure of the photosensitive agent, can be minimized. Thus, the photosensitive agent can be expected to have stable resolving performance.
In the arrangement example shown in FIG. 14 , the liquid supply nozzle 5 and liquid recovery nozzle 6 are arranged on the liquid contact surface 20 a , which is almost flush with the final surface 4 s . The peripheral portion 20 c is arranged outside the liquid supply nozzle 5 and liquid recovery nozzle 6 nearer to the wafer than the liquid contact surface 20 a , and the inert gas outlet portion 24 is arranged on the peripheral portion 20 c . The inert gas outlet portion nearer to the wafer than the liquid contact surface 20 a makes it possible to obtain a large pressure difference with a relatively small gas flow rate, suppress the running cost of the exposure apparatus, and minimize influences of the inert gas on the outside. The effect of the inert gas outlet portion can be obtained even if the inert gas outlet portion 24 is arranged within the liquid contact surface 20 a . In the arrangement examples shown in FIGS. 3 to 5 , an inert gas outlet portion, whose length is equal to or larger than that of the liquid supply nozzle 5 or liquid recovery nozzle 6 , can be provided outside the liquid supply nozzle 5 and liquid recovery nozzle 6 and upstream in the moving direction of the wafer.
Assume that a gas suction portion (suction ring) (not shown) is provided around the perimeter of the inert gas outlet portion 24 to suck and recover an inert gas ejected from the inert gas outlet portion 24 and discharge the sucked inert gas to a place which does not influence the surroundings of the exposure region. In this case, influences of the inert gas on the surroundings of the exposure region can be minimized. A typical example of the influences of the inert gas on the surroundings of the exposure region will be described. For example, the inert gas flows into the optical path of an interferometer, which measures the position of a wafer stage, or the optical path of an optical focus sensor, so that components of the gas in the optical path become nonuniform in view of time or space. This causes fluctuating measurement values and results in a measuring error.
As the inert gas, air or nitrogen from which moisture or an impurity, such as an organic substance, acidic gas, or alkaline gas, that may cause clouds in an optical system or may influence a photosensitive agent is sufficiently removed, is appropriately used. Particularly, use of nitrogen can prevent oxygen in the outer air from dissolving in the liquid with which the space below the final surface is filled. This use can prevent the contact surface with the liquid from being oxidized and corroded when pure water or functional water is employed as the liquid.
FIG. 15 is a view showing a preferred arrangement example of the liquid supply nozzle 5 . The outlet port of each of the liquid supply nozzles 5 shown in FIGS. 3 to 8 , 13 and 14 has a slit-like shape. On the other hand, in the arrangement example shown in FIG. 15 , one nozzle unit (discharge unit) 5 has n (a plurality of) nozzles J 1 to Jn. These nozzles J 1 to Jn are connected to the liquid supply unit 7 through on-off valves V 1 to Vn, respectively. By switching the operation of each of the valves V 1 to Vn corresponding to the nozzles J 1 to Jn, supply of a liquid can be started/stopped separately.
Such nozzles may be arranged not only in one line, but in a plurality of lines. In this case, the supply flow rate can be increased, and a liquid film can be formed to have a complicated shape.
The nozzle unit 5 , comprising a plurality of nozzles, can be controlled in the following manner. When immersion is to be performed from the peripheral border of the wafer, as shown in FIG. 16 , only the on-off valves corresponding to one of the plurality of nozzles under which the wafer is positioned are opened to supply the liquid. As the wafer moves, the on-off valves corresponding to one of the plurality of nozzles under which the wafer comes are sequentially opened to further supply the liquid onto the wafer. This can prevent the liquid from leaking from the wafer. This reduces the unit load for recovering the liquid.
FIG. 16 shows a case wherein the wafer moves and enters a region below the line of nozzles. The same applies to a case wherein the wafer comes off the region below the line of nozzles. Alternatively, a flush plate may be provided outside the wafer. In this case, supply of the liquid from each nozzle only needs to be controlled in accordance with the edge of the flush plate. This can minimize the size of the flush plate. As a result, the moving distance of the wafer can be reduced, and the size of the apparatus can be reduced.
In the arrangement example shown in FIG. 15 , supply/stop of the liquid from each unit of the nozzle units 5 is controlled by opening/closing the corresponding on-off valve. Alternatively, a function of discharging/stopping droplets can be embedded in each nozzle of the nozzle unit, as in, e.g., an inkjet printer. In addition to a continuous supply of the liquid, a substantially continuous liquid film can be formed by discharging droplets at a high frequency. More specifically, the structures and functions of, e.g., a bubble jet nozzle, thermal jet nozzle, or piezo-jet nozzle can be used.
According to the preferred embodiment of the present invention, in a projection exposure apparatus using immersion, a liquid film can be generated between a final surface and a substrate in a short period of time without splashing droplets. Also, generation of micro-bubbles during projection exposure can be suppressed. In addition, the need for operation of separately recovering the liquid for each substrate, for each alignment step before exposure, or for each step of maintaining the performance of the exposure apparatus, is eliminated. The projection optical system final surface can be coated with a liquid always having high purity, and the contact area with the ambient atmosphere can be reduced. Accordingly, a predetermined exposure and resolving performance can stably be obtained, and clouds due to an impurity contained in the environment or photosensitive agent can be suppressed or prevented. This allows high-precision and stable projection exposure without increasing the scale of an exposure apparatus and decreasing the productivity of the exposure apparatus. A fine pattern can be transferred onto a substrate stably and satisfactorily.
The manufacturing process of a semiconductor device using the above-mentioned exposure apparatuses will be described next. FIG. 17 shows the flow of the whole manufacturing process of the semiconductor device. In step 1 (circuit design), a semiconductor device circuit is designed. In step 2 (mask formation), a mask having the designed circuit pattern is formed.
In step 3 (wafer manufacture), a wafer is manufactured by using a material such as silicon. In step 4 (wafer process), called a preprocess, an actual circuit is formed on the wafer with the above-mentioned exposure apparatus by lithography using the prepared mask and wafer. Step 5 (assembly), called a post-process, is the step of forming a semiconductor chip by using the wafer formed in step 5 , and includes an assembly process (dicing and bonding) and a packaging process (chip encapsulation). In step 6 (inspection), the semiconductor device manufactured in step 5 undergoes inspections such as an operation confirmation test and a durability test of the semiconductor device manufactured in step 5 . After these steps, the semiconductor device is completed and shipped (step 7 ).
The wafer process in step 4 comprises the following steps. More specifically, the wafer process includes an oxidation step of oxidizing the wafer surface, a CVD step of forming an insulating film on the wafer surface, an electrode formation step of forming an electrode on the wafer by vapor deposition, an ion implantation step of implanting ions in the wafer, a resist processing step of applying a photosensitive agent to the wafer, an exposure step of transferring the circuit pattern onto the wafer having undergone the resist processing step using the above-mentioned exposure apparatus, a development step of developing the wafer exposed in the exposure step, an etching step of etching a portion except for the resist image developed in the development step, and a resist removal step of removing an unnecessary resist after etching. These steps are repeated to form multiple circuit patterns on the wafer.
The present invention can increase the practicality of an exposure technique using immersion and, more specifically, more reliably fill the gap between the final surface of a projection optical system and a substrate with a liquid, suppress contamination on the final surface of the projection optical system, simplify the structure of an exposure apparatus and reduce the size of the exposure apparatus, or the like.
As many apparently widely different embodiments of the present invention can be made without departing form 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 appended claims. | An exposure apparatus having a projection optical system configured to project a pattern of an original to a substrate and exposing a substrate to light via the original with a gap between the substrate and the projection optical system being filled with liquid. The apparatus includes a substrate stage configured to hold the substrate and to move, a supply nozzle configured to supply the liquid to the gap between the substrate and the projection optical system, the supply nozzle entirely surrounding the projection optical system, and a recovery nozzle arranged outside the supply nozzle and configured to recover the liquid from the gap, the recovery nozzle entirely surrounding said supply nozzle. | 6 |
FIELD OF THE INVENTION
The present invention pertains to commercial transactions conducted over a computer network, and more particularly to a system and method for selecting and purchasing a plurality of items on such a network.
BACKGROUND OF THE INVENTION
Conducting commercial transactions over computer networks such as the Internet is commonplace today. As the number of Internet shoppers continues to increase, the number and corresponding dollar value of goods and services, i.e., items, purchased electronically in such manner also continues to increase. However, conventional techniques for searching for items to be purchased, are searching, viewing specifications and prices, and selecting for purchase of such items, one item at a time.
Specifically, in order to conduct such transactions today, a consumer has to search for such items one at a time by accessing and browsing web pages of a website, one web page and one website at a time. Searching for and purchasing items of interest in this manner is a very tedious, time consuming and frustrating process. Even the most sophisticated and advanced shopping search engines, such as www.MySimon.Com, which enables a shopper to enter product specifications, and then searches for the websites of participating merchants that may carry the items being searched, still requires that searching and purchasing be done one item at a time, one web page and one website at a time. Accordingly, it is an objective of the present invention to overcome the foregoing drawback.
SUMMARY
A system and method for conducting commercial transactions over the Internet, whereby a shopper, by using one search command, can simultaneously search for a plurality of items on at least one website in a single search action. The shopper specifies items of interest to be searched, and in one embodiment can also specify and/or exclude websites to be searched. In additional embodiments, the system searches a selectively alterable set of default or server recommended websites. To use the invention, the shopper enters a list of items in response to a series of prompts. Under one search command, the system then simultaneously searches for all of the specified items on the default site, the system recommended site(s), or site(s) specified by the shopper, or all of the above in another embodiment. Information regarding the items retrieved as a result of the search is then displayed for viewing by the shopper. The shopper can simultaneously purchase selected ones of said items.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 a , 1 b , and 1 c show a flowchart depicting an example operation of the present invention. A selective subset of these steps can be implemented for desired application.
DETAILED DESCRIPTION OF THE INVENTION
The present invention enables a shopper to selectively designate a plurality of items which they wish to purchase, simultaneously conduct a search for said items on a plurality of websites, view information found regarding the specified items, and then purchase all or some of these items. This enables shoppers to search for and purchase items without having to engage in the tedious and time-consuming process of searching for items one at a time, one web page and one website at a time as is conventionally done. The user can also simultaneously search for different types of items using the present invention.
The system and method of the present invention is implemented by software. The software is used in conjunction with a website that the shopper would visit to shop for items to be purchased. The software presents a series of on-screen prompts in response to which the shopper specifies the items to be searched and specifies information/preferences and/or answers questions regarding the items so that a search can be conducted for such items. The software alternately causes a search to be conducted on a default website, website(s) specified by the shopper, and/or on a selectively alterable set of default website(s), recommended website(s) specified by an intelligent software, or all of the above. The results of the search are then compiled, formatted, and displayed on a display device for viewing by the shopper who can purchase selected ones or all of the items found in the search, or further refine the search.
FIGS. 1 a , 1 b , and 1 c show a flow chart depicting an example operation of the present invention. A selection of steps illustrated can be implemented for a desired application. At step 1 , a shopper enters via keyboard, mouse, stylus, voice or otherwise, a list of the items they wish to purchase at a default site the shopper visits for such items. Alternatively, a shopper can select items to be searched from a default list of items offered by a project program such as a meal preparation program, by checking boxes for ingredients to be purchased from a website that sells food products. At step 2 , the shopper reviews the shopping list. At step 3 , the shopper decides whether to edit the shopping list. If the shopper wants to edit the shopping list, then the shopper does so at step 4 and the shopper can review the edited list at step 2 . If at step 3 , the shopper decides not to edit the shopping list and the default site is not a portal, at step 20 the list is sent to the site server. At step 21 the search is conducted on the default site. The process then proceeds to step 13 in FIG. 1 c . If the default site is a portal on which the software is running, at step 5 the shopper is prompted to indicate whether he wants to specify any particular website or sites to be searched. If the shopper decides to specify a preferred website or sites, then at step 6 in FIG. 1 b the shopper specifies such site or sites and/or excludes site or sites to be searched for some or all of the items in the shopping list. If at step 5 the shopper declines to specify a preferred website, in step 52 the shopping list is sent to the portal server for system recommendation for site(s) to search at step 17 in FIG. 1 c.
At step 7 in FIG. 1 b , the shopper views the list of website(s) he specified. At step 8 , the shopper is prompted to indicate whether he wishes to edit the list of website(s) he specified. If so, then at step 9 , the shopper edits the list of website(s), and then at step 7 views the edited list of site(s). If however, at step 8 , the shopper decides not to edit the list of website(s) they specified, then at step 10 the list of specified site(s) is sent to the server of the website on which the software is running. At step 11 , the server can approve good site or sites and reject problem site or sites. At step 12 the server searches approved sites, and if so desired, also search the system recommended sites for the items on the shopping list for comparison.
At step 13 , the server writes the results, i.e., data gathered, of the search for all of the items from all of the sites searched into a file and formats the file. At step 14 , the server sends the file to the shopper's access device. The file can be presented to the shopper in any form, including in a series of lists, wherein each list corresponds to items found on different websites or databases, or wherein each list is comprised of similar types of items or similarly priced items. The list of items can be presented for viewing by the shopper using any desired criteria. At step 15 , the shopper reviews the file and selects and approves for purchase those items he desires, and such approval is sent to the server. At step 16 , the server places an order at the appropriate website or sites for the items selected and approved for purchase by the shopper and then send a confirmation to the shopper.
If at step 11 , the server rejects all websites specified by the shopper as problem sites, then at step 17 the server returns the list of specified sites together with reasons for rejection, and a list of recommended sites to the shopper. At step 18 , if so desired, the shopper can choose and prioritize the system recommended sites, or selects to search all system recommended sites at the default prioritization recommended by the server. At step 19 , the revised list of sites is then sent to the server for search at step 12 , from where the process continues as previously described above.
If at step 5 the shopper does not specify any website, then the list of items to be purchased are sent at step 20 to the server. The server returns the list of recommended sites at step 17 , from which point the process continues as previously described above.
It will further aid in understanding the operation of the present invention to consider the following example. If a shopper wants to shop for ingredients for a meal, the recipe or recipes for the meal are presented on-screen with a check box in front of each ingredient on the list of required ingredients, along with option entry blanks for the shopper to select or exclude items and to indicate other information such as how many servings are to be prepared to automatically populate an editable quantity column.
After the shopper enters their preferences/selections, the shopper is presented with a list of suppliers from whom they can purchase the goods. The shopper then selects and prioritizes the list of suppliers in order of descending preference. The website or database of the first most preferred supplier is then searched for the desired items on the list, and data regarding said items is collected and compiled. Then the website or database of the second most preferred supplier is searched for the specified items with said data being collected and compiled. The websites or databases of the remaining suppliers are similarly searched in order of descending preference.
The search results are then displayed for viewing by the shopper in a plurality of lists including product information, e.g., brand and price information, for each item with a separate list being displayed for each of the respective suppliers. If items are not available from the first most preferred supplier while available from the next most preferred supplier, those items would be listed separately in the first most preferred supplier search result list as being available from the next, e.g., second, most preferred supplier from whom they could be purchased. If the desired items are not available from the first or second most preferred supplier while available from the third most favored supplier, such items would be listed separately in the first most preferred supplier search result list as being available from the next, e.g., third, most preferred supplier. Similarly, if in the search result list for the second most preferred supplier there are items not available from the second most preferred supplier, the list would indicate whether those items were available from the first most preferred supplier, from the third most preferred supplier or from other suppliers in descending order of preferred suppliers.
The shopper then chooses one search list of goods, and places an order for the entire list of items at one time. Alternatively, the shopper can query for various search result listings using different criteria, and choose and place an order for goods from said different lists, for example, for price optimization. The software program then automatically places orders at the specified suppliers for all of the items in the list, and sends one confirmation to the shopper when the process is completed.
The present invention is implemented using software which can be written in many programming languages, or implemented with many data and information displaying or web-page generation tools. The present invention can be used on a global or local computer network, on a personal computer, on viewable storage media such as a CD or DVD, on a wireless telephone, on a wireless personal assistant such as a Palm Pilot, or on any type of wired or wireless device that enables digitally stored information to be viewed and internet access. Also, information displayed and viewed using the present invention can be printed, stored to other storage medium, and electronically mailed to third parties.
Numerous modifications to and alternative embodiments of the present invention will be apparent to those skilled in the art in view of the foregoing description. Accordingly, this description is to be construed as illustrative only and is for the purpose of teaching those skilled in the art the best mode of carrying out the invention. Details of the embodiment may be varied without departing from the spirit of the invention, and the exclusive use of all modifications which come within the scope of the appended claims is reserved. | The present invention is a system for conducting commercial transactions over the Internet, whereby a shopper can simultaneously search for a plurality of items on at least one website with a single search command. The shopper can selectively specify the items of interest to be searched and can also specify and/or exclude websites to be searched. The system also searches a selectively alterable set of default website(s) and intelligently recommended website(s). Under one search command, the system simultaneously searches for all of the items on any combination of the following: site(s) specified by the user, a default website, an alterable set of default or intelligently recommended website(s). Information regarding the items retrieved as a result of the search is compiled under an alterable set of criteria, and displayed for viewing by the shopper. The shopper can simultaneously purchase selected ones of said items with one order command. | 6 |
BACKGROUND OF THE INVENTION
[0001] The present invention relates generally to suspended ceiling systems and more particularly to novel ceiling panels that are designed to create a multi-planar appearance when installed into a horizontally oriented grid structure.
PRIOR ART
[0002] Suspended ceiling systems typically include grid members that provide for oppositely extending ceiling panel support flanges. The grid members are interconnected to form a grid and are suspended from the structure of a building with wire hangers or rods. In these systems, the edges of the ceiling panels are installed by laying the panels in the grid opening created by the grid members. Once the ceiling panels are installed into the grid, a uniform ceiling surface is created. Suspended ceiling panels are manufactured from gypsum or slag wool fiber and are designed to conceal pipes, wiring and the like, while still allowing access to the concealed space above the ceiling. Typical ceiling panels are fabricated out of sound deadening and insulating material and are designed to meet fire safety codes. The acoustical panels are planar appearance and do little to enhance a room's décor. The acoustical panels also may include surface impressions and markings to enhance their appearance. When the panels are installed in the grid, the overall appearance of the ceiling is a generally planar. Prior art panels do not provide for a ceiling system that utilizes tapered ceiling panels to vary the appearance of the ceiling.
SUMMARY OF THE INVENTION
[0003] This invention may be described as novel ceiling panels that are used with a corresponding grid system to create a multi-planar ceiling system. The panels, can be installed in the grid system in different arrangements to create various patterns including shingles, saw teeth, undulations, pin wheels, among others and are designed to enhance the appearance of retail and office space that utilize suspended ceilings to conceal the building structure. The ceiling is comprised of a grid system made up of intersecting grid members suspended from the building structure with hangers. The grid members are interconnected with grid clips to form openings that accept the panels. The grid members are rigid preformed members that include a base portion, a bridge portion and a bulb portion. The base portion is perpendicularly oriented to the bridge member and is adapted to support the panels. The panels are square when viewed in plan view but have a tapered cross-section about all or part of the panels. The panels can be fabricated out of plastic, gypsum, slag wool, or metal, and can be opaque or translucent. The panels are arranged in the grid in a fashion so that certain repeating patterns are formed when viewed from below. To create a shingled pattern, all of the panels are arranged in the same direction. To create a saw-tooth pattern, the direction of the panels are alternated in adjacent rows.
[0004] These and other aspects of this invention are illustrated in the accompanying drawings, and are more fully described in the following specification.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] [0005]FIG. 1 is a perspective view of the ceiling system of the present invention with the panels oriented in a saw-tooth pattern;
[0006] [0006]FIG. 2 is a cross-section of FIG. 1 taken along line 2 - 2 illustrating the panels suspended from grid members;
[0007] [0007]FIG. 3 is a perspective view of a tapered ceiling panel supported by a pair of intersecting grid members.
[0008] [0008]FIG. 4 is a perspective view of the ceiling system of the present invention with the panels oriented in a shingle pattern;
[0009] [0009]FIG. 5 a is a cross-section of FIG. 4 taken along line 5 - 5 illustrating the panels suspended from horizontal grid members;
[0010] [0010]FIG. 5 b is a variation of the grid system of FIG. 4 in that the grid system is sloped to alter the elevation of the panels;
[0011] [0011]FIG. 6 is a perspective view of the ceiling system of the present invention with the panels oriented in an alternating row undulating pattern;
[0012] [0012]FIG. 7 is a cross-section of FIG. 6 taken along line 7 - 7 illustrating the panels suspended from the grid members;
[0013] [0013]FIG. 8 is a perspective view of the ceiling system of the present invention with the panels oriented in an alternate undulating pattern;
[0014] [0014]FIG. 9 is a cross-section of FIG. 8 taken along line 9 - 9 illustrating the panels suspended from the grid members;
[0015] [0015]FIG. 10 is a perspective view of the ceiling system of the present invention with the panels oriented in a pinwheel pattern;
[0016] [0016]FIG. 11 is a cross-section of FIG. 10 taken along line 11 - 11 illustrating the panels suspended from the grid members;
[0017] [0017]FIG. 12 is a perspective view of the ceiling system illustrating a transition from a first elevation to a second elevation by use of tapered panels;
[0018] [0018]FIG. 13 is a cross-section of FIG. 12 taken along line 13 - 13 illustrating the panels suspended from the grid members;
[0019] [0019]FIG. 14 is a perspective view of the ceiling system illustrating the use of flat panels with various depths to create a tiered pattern;
[0020] [0020]FIG. 15 is a cross-section of FIG. 14 taken along line 15 - 15 illustrating the panels suspended from the grid members;
[0021] [0021]FIG. 16 is a perspective view of the ceiling system illustrating the use of flat panels with two depths to create a checkerboard pattern;
[0022] [0022]FIG. 17 is a cross-section of FIG. 16 taken along line 17 - 17 illustrating the panels suspended from the grid members;
[0023] [0023]FIG. 18 is a perspective view of a tapered ceiling panel;
[0024] [0024]FIG. 19 is a perspective view of a tapered transition panel;
[0025] [0025]FIG. 20 is a perspective view of another tapered transition panel;
[0026] [0026]FIG. 21 is a perspective view of a shallow flat panel;
[0027] [0027]FIG. 22 is a perspective view of a deep flat panel;
[0028] [0028]FIG. 23 is a cross-sectional view of a pair of tapered panels supported by a grid member;
[0029] [0029]FIG. 24 is a cross-sectional view of an alternate pair of tapered panels connected to a channel type grid member.
DETAILED DESCRIPTION OF THE INVENTION
[0030] While the present invention will be described fully hereinafter with reference to the accompanying drawings, in which a particular embodiment is shown, it is understood at the outset that persons skilled in the art may modify the invention. Accordingly, the description which follows is to be understood as a broad informative disclosure directed to persons skilled in the appropriate arts and not as limitations of the present invention.
[0031] [0031]FIG. 1 illustrates a portion of an assembled multi-planar ceiling system 10 with the panels arranged in a saw-tooth pattern. The multi-planar ceiling system 10 is comprised of a grid 12 that is made up of a plurality of intersecting grid members 14 . The grid members 14 are arranged to form openings 16 that are sized to receive tapered panels 18 . The grid 12 is suspended from a building structure by wire hangers 13 or other supporting devices and, when the panels are installed, it is designed to conceal utilities.
[0032] The grid members 14 , shown best in FIG. 3, have a T-shaped cross section and include a horizontally oriented base member 20 , a bulb portion 22 and a bridge member 24 interconnecting the bulb portion 22 to the base member 20 . The bridge member 24 includes a plurality of openings 25 to allow for the attachment of hanger devices and to allow for the attachment of grid clips 26 . The grid members 14 are manufactured in three preferred lengths, 12 feet, 4 feet and 2 feet, although other lengths may be used. To create the grid structure 12 , a row of parallel evenly spaced grid members 14 are suspended by wire hangers. Each row of grid members 14 are spaced apart to accommodate the size of the tapered panels 18 . To accommodate a 2-foot by 2-foot ceiling panel, the grid members 14 would be spaced apart 2 feet on-center. The grid 12 also includes a second set of grid members 28 that are perpendicularly oriented in relation to the first set of grid members 14 to create the opening 16 required for suspending the panels 18 . The tapered panels 18 , as illustrated in FIG. 1, are arranged so that the panels 18 in a first row 30 are positioned in a direction that is 180 degrees out of phase with the panels 18 in a second row 32 . This arrangement creates a saw-tooth appearance when the ceiling system 10 is viewed from below. FIG. 2 illustrates the orientation of the panels 18 in the grid 12 when positioned to form the saw tooth pattern. The tapered panels 18 , as shown in FIG. 3, have a square configuration and includes four upwardly extending sides 34 , 36 , 38 and 40 interconnected by a tapered bottom layer 42 . Each of the four sides 34 , 36 , 38 and 40 includes an upper end 44 with an outwardly extending flange 45 that is adapted to be supported by the base member 20 of the grid members 14 . The flange 45 is oriented to the sides 34 , 36 , 38 and 40 at an angle that allows the sides 34 , 36 , 38 and 40 of the panel 18 to be substantially parallel to the bridge portion 24 of the grid members 14 . The first side 34 opposes the second side 36 and is rectangular in shape. The first side 34 of the panel 18 has a surface area that is larger than the second side 36 . The third and fourth sides 38 and 40 are triangular shaped tapering from the first side 34 to the second side 36 . The flanges 45 of the sides 34 , 36 , 38 and 40 all lie in the same plane so they can be supported by the grid members 14 . The panels 18 can be fabricated out of sheet steel where they are formed into the desired configuration. Faces of the panels can be perforated or slotted. The panels can also be thermoformed or molded out of plastic to create the desired panel. Plastic panels can be made either translucent or opaque depending upon whether lighting is used or if a certain optical effect is required by the architect.
[0033] [0033]FIG. 4 illustrates the tapered ceiling panel system 10 wherein the tapered panels 18 are arranged in a uniform direction in the grid 12 to create a shingle pattern. The panels are arranged so that the first side 34 of the panels 18 are all facing the same direction. FIG. 5 a is a cross section taken along line 5 - 5 of FIG. 4 illustrating the orientation of the panels 18 in the grid 12 . The panels 18 are oriented in the grid 12 so that the first side 34 of a first panel 18 is adjacent to the second side 36 of a second panel 18 .
[0034] [0034]FIG. 5 b illustrates the ceiling system 10 wherein the rows of parallel grid members 14 are arranged having varied elevations so that the base member 20 of a grid member 28 is higher than the base member 20 of adjacent grid member 28 . The panels 18 are arranged in the grid so that the flange 45 of the first side 34 is connected to the grid member 28 of a higher elevation than the flange 45 of the second side 36 , which is connected to the grid member 28 of the lower elevation. With this grid arrangement, the bottom layer 42 of the panels are parallel with the floor of the building structure.
[0035] [0035]FIG. 6 illustrates the tapered panel ceiling system 10 wherein the tapered panels 18 are arranged to form an alternating undulating pattern. The panels 18 in the first row 30 are arranged so that similar sides of adjacent panels 18 are abutting. The second row 32 of panels 18 are arranged in a similar fashion but are oriented out of phase from the first row. FIG. 7 illustrates the second sides 36 of adjacent panels 18 in the first row 30 are in line with the first sides 34 of adjacent panels 18 in the second row 32 creating an alternating undulating pattern.
[0036] [0036]FIG. 8 illustrates the tapered panel ceiling system 10 where the tapered panels 18 are arranged to form a uniform undulating pattern. The panels 18 are arranged in the grid 12 so that similar sides of the panels 18 are abutting. FIG. 9 illustrates that the panels 18 in each row are oriented with the first side 34 of the first panel 18 adjacent with a first side 34 of the second panel 18 .
[0037] [0037]FIG. 10 illustrates the tapered panel ceiling system 10 where the tapered panels 18 are arranged to form a pinwheel pattern. To create the pinwheel effect, the panels 18 are arranged 90 degrees out of phase with an adjacent panel 18 . The second side 36 of a first panel 48 is adjacent to the third side 40 of a second panel 50 . The second side 36 of the second panel 50 is adjacent to the third side 40 of a third panel 52 . The second side 36 of the third panel 52 is adjacent to the third side 40 of a fourth panel 54 . The orientation of the four panels 48 , 50 , 52 and 54 creates a pinwheel quadrant 56 . The remainder of the grid 12 is filled in with pinwheel quadrants 56 of the same configuration, creating a repeating pinwheel pattern. FIG. 11 illustrates a cross-section of FIG. 10 illustrating the arrangement of the four panels 48 , 50 , 52 and 54 that make up a pinwheel quadrant 56 . Each panel 48 , 50 , 52 and 54 is supported by the grid members 28 .
[0038] [0038]FIG. 12 illustrates a variable depth ceiling system 58 where five different panels 62 , 64 , 18 , 68 and 70 are utilized to transition the ceiling 58 from a high elevation 72 to a low elevation 74 . The higher elevation 72 is comprised of the shallow panels 62 with panel faces that are closer to the grid 12 . The lower elevation 74 is comprised of the deep panels 64 that extend the panel faces further away from the grid 12 . The shallow panels 62 transition to the deep panels 64 by use of the tapered panels 18 . To transition from the shallow panels 62 to the deep panels 64 in a corner region, two different transition panels are used. The first transition panel 68 , shown in FIG. 20, includes two edges 76 and 78 having a depth equal to the shallow panel 62 and two edges 80 and 82 that are tapered to transition from the high elevation 72 to the low elevation 74 . The second transition panel 70 , shown in FIG. 19, includes two side edges 84 and 86 having a depth equal to the deep panel 64 and two edges 88 and 90 that are tapered to transition from the high elevation 72 to the low elevation 74 . FIG. 13 is a cross-section taken along line 13 - 13 of FIG. 12 illustrating the deep panel 64 , the shallow panel 62 , the tapered panel 18 , the first transition panel 68 and the second transition panel 70 all suspended from the grid members 28 .
[0039] [0039]FIG. 14 illustrates a variable depth ceiling system 92 having a stepped transition from a high elevation 94 to a low elevation 96 . The ceiling system 92 is made up of four different panels 98 , 100 , 102 and 104 to complete the transition from the high elevation 94 to the low elevation 96 . FIG. 15 is a cross-section taken along line 15 - 15 of FIG. 14 illustrating the transition from the shallow panel 98 to the deep panel 104 by using the two intermediate panels 100 and 102 .
[0040] [0040]FIG. 16 illustrates a variable depth ceiling system 106 utilizing alternating shallow panels 108 and deep panels 110 to create a checkerboard effect. The panels 108 and 110 are designed to fit into a standard grid opening 16 . FIG. 17 is a cross-section taken along line 17 - 17 of FIG. 16 and illustrates the panels 108 and 110 suspended from a set of parallel grid members 28 .
[0041] FIGS. 18 - 20 illustrate the tapered panel 18 and the two transition panels 68 and 70 used to create the ceiling system 58 illustrated in FIG. 12. The first transition panel 68 , as shown in FIG. 20, includes the first and second edges 76 and 78 that are rectangular in shape and adapted to transition to the shallow panels 62 . The first and second edges 76 and 78 include flanges 112 that are used to support the panel 68 to the base member 20 of the grid members 14 and 28 . The flanges 112 are oriented to allow the edges 76 , 78 , 80 and 82 of the panel 68 to be substantially parallel to the bridge portion 24 of the grid members 14 and 28 . The third and fourth edges 80 and 82 are tapered from the first and second edges 76 and 78 to a corner of the panel 68 and also include the flanges 112 used to support the panel 68 from the base member 20 of the grid members 14 and 28 . The panel 68 further includes a face surface 116 that includes a diagonal ridge 118 that divides the panel allowing the face surface 116 to transition from the first and second edges 76 and 78 to the third and fourth edges 80 and 82 .
[0042] The second transition panel 70 , as shown in FIG. 19, includes the first and second edges 84 and 86 that are rectangular in shape and are adapted to transition to the deep panel 64 . The first and second edges 84 and 86 include flanges 120 that are used to support the second transition panel 70 to the base member 20 of the grid members 14 and 28 . The third and fourth edges 88 and 90 are tapered from the first and second edges 84 and 86 to a corner 122 of the panel 70 and also include the flanges 120 used to support the panel 70 from the base member 20 of the grid members 14 and 28 . The panel 70 further includes a face surface 124 that includes a diagonal valley 126 that divides the panel allowing the face surface 124 to transition from the first and second edges 84 and 86 to the third and fourth edges 88 and 90 .
[0043] [0043]FIG. 21 illustrates the shallow panel 62 used in the ceiling systems depicted in FIGS. 12, 14 and 16 . The shallow panel 62 has four uniform sides 128 that include outwardly extending flanges 130 to support the panel 62 from the grid 12 . FIG. 22 illustrates the deep panel 64 also used in the ceiling systems depicted in FIGS. 12, 14 and 16 . The deep panel 64 has four uniform sides 132 that include outwardly extending flanges 134 to support the panel 64 from the grid 12 .
[0044] [0044]FIG. 23 is a cross section of the tapered ceiling system 10 illustrating the connection of the tapered panels 18 to the grid members 14 or 28 . The flanges 46 extend outwardly from the sides of the panel 18 and are adapted to rest upon the base member 20 of the grid members 14 or 28 . FIG. 24 is an alternate embodiment of the attachment of tapered panels 136 to channel-type grid members 138 . The channel-type grid members 138 include a bulb portion 140 a base portion 144 and a bridge portion 142 interconnecting the base portion 144 to the bulb portion 140 . The base portion 144 includes a channel 146 that is adapted to support the panel 136 . The panel 136 includes sides 148 that include inwardly extending detents 150 that are adapted to retain the panel 136 to the grid member 138 .
[0045] The use of the tapered panels 18 in a planar grid 12 allows for various ceiling patterns to be configured by simply repositioning the panel in the grid 12 . Since the panels 18 are not permanently installed, the panels 18 can be rotated within the grid 12 at a later date to alter the ceiling design.
[0046] Various features of the invention have been particularly shown and described in connection with the illustrated embodiment of the invention, however, it must be understood that these particular arrangements merely illustrate, and that the invention is to be given its fullest interpretation within the terms of the appended claims. | The present invention relates to a novel ceiling panel that is used with a corresponding grid system to create a shingle-type ceiling structure. The panels, are arranged in the grid system to create various patterns including shingles, saw teeth, undulations, pin wheels, among others and are designed to enhance the appearance of retail and office space. The ceiling is comprised of a grid system made up of intersecting grid members suspended from the building structure with hangers. The grid members are rigid preformed members that include a base portion a bridge portion and a bulb portion. The base portion is perpendicularly oriented to the bridge member and is adapted to support the panels. The panels are square when viewed in plan view but have a tapered cross-section about all or part of the panels. The panels can be fabricated out of polycarbonate or metal and can be opaque or translucent. The panels are arranged in the grid in a fashion so that certain repeating patterns are formed when viewed from below. | 4 |
BACKGROUND OF THE INVENTION
The present invention relates to a machine for filling and closing bags of a synthetic plastic material, preferably lateral fold bags or flat bags.
Machines of the above-mentioned general type are known in the art. A known machine has lowerable filling pipes and an intermittently moveable transport band for the filled bags, wherein two carriages are arranged in the space between the filling pipes and the transporting band at a distance corresponding to the bag width and moveable synchronously with the transporting band parallel to its longitudinal direction. Such a machine is disclosed, for example, in a German patent application No. P 30 06 129.1-27. The carriage pair is provided with several gripper pairs and performs, in addition to a horizontal movement, a pivoting movement about a horizontal axis so as to separate the bag mouth edge by the gripper pair from the filling pipes and move in the region of the welding station into the space between the welding members. The known machines possess some disadvantages in the sense of their efficiency and space they occupy.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a machine for filling and closing bags of a synthetic plastic material, preferrably lateral fold bags or flat bags, which avoids the disadvantages of the prior art.
More particularly, it is an object of the present invention to provide a machine of this type which has a higher efficiency and occupies a smaller space, as compared with the known machines.
In keeping with these objects and with others which will become apparent hereinafter, one features of the present invention resides, briefly states, in a machine in which a carriage pair is provided with a feeding device having two feeding arms which move with their gripping plates in an opening station from an upper position into a bag mouth to a medium expanding position and after expanding of the bag moves transverse to the movement direction of the carriage pair to a lower transporting position, and the carriages have gripper pairs at both sides of the feeding device, of which a front gripper pair brings an empty bag to the opening station and a rear gripper pair brings the filled bag from the filling station to a welding station with holding the bags under the bag mouth edges.
When the machine is designed in accordance with the present invention, an empty bag in one working step is transported to the opening station, a bag transported in the preceding working step from the feeding device to the opening station is brought in fed condition to the filling station, and a filled bag is brought in closed condition to the closing station, so that in the further working process simultaneously a bag is opened, a bag is filled, and a filled bag is closed by a weld seam. At the smae time, the gripper pair opens the bags located alterally at a distance from the working place, the gripping plates of the feeding arms pivot inwardly and upwardly, and the carriage pair moves back prior to ending of the working cycle to conduct a next one.
The machine can be combined with an aggregate for producing bags from a hose foil. For obtaining sufficient cooling for the bottom weld seam of the finished bags, a gripper chain pair can be provided between the bag manufacturing aggregate and the carriage pair, whereby the empty bags are supplied to the front grippers of the carriage pair. During this transport path, the bottom weld seams are cooled so that they can be fully loaded.
The novel features which are considered as characteristic for the invention are set forth in particular in the appended claims. The invention itself, however, both as to its construction and its method of operation, together with additional objects and advantages thereof, will be best understood from the following description of specific embodiments when read in connection with the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a schematic lateral view of the machine in accordance with a first embodiment of the present invention;
FIG. 2. is a schematic lateral view of the machine in accordance with a second embodiment of the invention;
FIG. 3 is a lateral view of the machine in accordance with a first embodiment;
FIG. 4 is a lateral view of a welding device in according with FIGS. 1 and 2;
FIG. 5 is a plan view of the welding device of FIG. 4;
FIG. 6 is a plan view of a carriage pair in which only one carriage is shown;
FIG. 7 is a front view of a feeding device;
FIG. 8 is a plan view of the feeding device of FIG. 7;
FIG. 9 is a lateral view of the feeding device of FIG. 7;
FIG. 10 is a view of a suspension for the welding device; and
FIG. 11 is a plan view of the suspension of FIG. 10.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A machine for filling and closing bags of a synthetic plastic material shown in FIG. 1 has a roll off station 1 for a hose foil web 2, a pair of pulling rollers 3 driven intermittently in accordance with a cycle of the machine, and an accumulating device 4 for the hose foil web 2 incoming during stoppage of the roller pairs 3 from the roll-off station 1, a welding device 5 for producing a bottom weld seam, an opening station 6, and a filling station 7, a welding device 8 for closing the filled bags, and a conveyor transporting band 9 for transporting of the filled bags.
In the embodiment shown in FIG. 2 a cooling station is additionally arranged between the welding device 5 and the opening station 6, and an additional welding device 11 is arranged after the welding device 8. Moreover, prior to the roller pair 3, as considered in running direction of the foil web 2, an additional welding device 12 is arranged for pre-welding and corner welding.
The welding device 5 is shown in FIGS. 4 and 5. Welding members or dies 13 and 14 are mounted on levers 15 and 16. The levers 15 and 16 are floatingly supported on axles 17 at both sides. At both sides of the welding members 13 link rods 19 acting upon double levers 18 are articulately connected. Link rods 20 are similarly articulately connected with the welding member 14 at both sides and act upon the double lever 18. The double lever 18 is connected with the pins of a throughgoing pivot axle 21 for joint rotation therewith.
A cylinder-and-piston unit 23 acts upon the pivot axle 21 via a lever 22. As seen in the running direction of the foil web 2, a stationary clamping member 24 is arranged below the welding member 14. A clamping member 26 is mounted on a lever 25 and is pivotable about the horizontal axles 17. Cylinder-and-piston units 27 are connected with the levers 25 at both sides. As can be particularly seen from FIG. 4, the axles 17 are located in the running plane of the foil web 2. Thereby, good adjustability of both the welding members 13 and 14, and also of the moveable clamping member 26 is provided. The levers 15, 16 and 25 which carry the welding members 13 and 14 and the clamping member 26 require only low structural expenditures. As seen in the running direction of the foil web 2, a funnel-shaped guiding plate 28 is mounted prior to the welding members 13 and 14.
A displaceable separating cutter 29 is arranged between the welding member 14 and the stationary clamping member 24 transverse to the foil web. The separating cutter 29 is mounted in a cutter holder 30 which is fixedly connected with the piston of a cylinder-and-piston unit 31.
FIG. 6 shows a pair of carriages 32 which are moveable from guide rods 33 and 34 at both sides in horizontal planes. Grippers 36 and 37 are pivotably supported on the carriage pair 32. Link rods 38 and 39 are articulately connected with the grippers 36 and 37 and are coupled at the opposite end by a shackle 40. A cylinder-and-piston unit 41 which is also arranged on the carriage pair 32 and centrally on the shackle 40.
The opening station 60 includes links 85 and 86 forming a parallel guide, and suction pipes 42 and 43 mounted thereon and actuated by a cylinder-and-piston unit 44. For adjusting the distance of the suction pipe 42 and 43 to the bag opening resulting from the bag shape and bag dimensions, an adjustable abutment 87 for the suction pipe 43 is arranged. Displacing of the abutment 87 provides for central displacement of both suction pipes 42 and 43 as can be seen from FIG. 3.
A bag feeding device 45 is arranged on the carriage pair 32 shown in FIGS. 7-9 for a machine side. A gripping plate 46 is bent at its end facing toward the machine center and screwed on a feeding arm 47. The feeding arm 47 is fixedly clamped on a horizontal axle 48 which is pivotally supported in a plate 51 connected via links 49 and 50 with the carriage pair 32. A lever 52 is fixedly clamped on the horizontal axle 48.
A cylinder-and-piston unit 53 is articulately connected with the plate 51, and an additional cylinder-and-piston unit is articulately connected with the lever 52. The cylinder-and-piston unit 53 is coupled with the cylinder-and-piston unit 54 via a connecting piece 55. Further, a cylinder-and-piston unit 57 is pivotally connected with the carriage 32 and acts transverse to the carriages 32 onto the link 50 for displacement of the feeding arm 47. The displacement is limited by an abutment 56.
Further grippers 58 and 59 are pivotally supported on the carriage pair 32. Link rods 60 and 61 are articulately connected with the grippers 58 and 59 and coupled with one another via a shackle 62. A cylinder-and-piston unit 63 mounted on the carriage pair 32 is articulately connected with the shackle 62.
In the embodiment shown in FIG. 2, further grippers 58' and 59' which are identical to the grippers 58 and 59 are provided. These grippers 58' and 59' with the actuating elements are fixedly connected with the carriage pair 32. As can also be seen from FIG. 2, a cooling station 10 is arranged between the welding device 5 and the opening station 6. Several gripper pairs 65 are mounted on an endless gripper chain 64. A cooling device 66 is located under the endless gripper chain 64.
As can be seen from FIG. 1, the conveyor transporting band 9 is adjustable with respect to its height. On a not-shown frame, spindles 58 are arranged and driven via a chain drive 69 from a drive motor 70. The spindles 68 are supported by abutments 71 arranged in pipes 67.
FIGS. 10 and 11 show a suspension of the welding devices 5 and 8. Frames 62 and 63 which support parts of the machine are provided with holders 74 and 75 bent at one end. The holders 74 and 75 carry an angle-shaped rail 76 which rests on screws 77 which are screwed in bent ends of the holders 74 and 75. Individual parts which belong to the welding devices 5 and 8 are carried by a frame 78 which lies on the angular rail 76.
The machine in accordance with the present invention operates in the following manner:
The roller pair 3 which is driven intermittently in accordance with the working pace of the machine pulls the hose foil web 2 in correspondance with the bag length. The welding members 13 and 14 and the clamping members 24 and 26 are displaced from one another so that the foil web 2 can run under the action of the roller pair 3 unobjectionably through the welding station 5. The foil web 2 is transported through guiding plate 28 centrally through the welding device 5. By actuating of the cylinder-and-piston units 27, the moveable clamping members 26 are pressed against the stationary clamping member 24. After this, the cylinder-and-piston unit 31 is actuated. The separating cutter 29 moves thereby transverse to the foil web 2, so that the hose piece corresponding to the bag length is separated from the foil web 2. After closing the clamping members 24 and 26, the cylinder-and-piston unit 23 is actuated so that the welding members 13 and 14 are pivoted in opposite directions and closed for formation of a bottom weld seam. Before the moveable clamping members 26 are opened by repeated actuation of the cylinder-and-piston units 27, the grippers 36 and 37 brought on the carriage pair 32 take the bag separated from the foil web 2. Before taking the bag, the carriage displaces in its right end position, as can be seen in FIG. 1. The carriage pair 33 is displaceably supported on the guide rods 33 and 34 and move by a cylinder-and-piston unit 79 with the pace of the machine from its right end position to its left end position. The grippers 36 and 37 are closed by actuation of the cylinder-and-piston unit 41. After closing of the grippers 36 and 37, the cylinder-and-piston unit 79 is actuated, whereby the carriage pair 32 is displaced to its left end position. The bag is thereby transported to the opening station 6.
The upper end which are not welded is opened by the suction pipes 42 and 43. By switching the cylinder-and-piston unit 41, the grippers 36 and 37 are opened and the carriage pair 33 is displaced by switching of the cylinder-and-piston unit 79 to its right end position. The gripping plate 46 mounted on the feeding arm 47 arrives thereby in the region of the opened bag. By a not-shown control of the cylinder-and-piston units 53 and 54, the feeding arm 47 is displaced in such a position that the gripping plate 46 lies relative to the upper end of the bag higher. By actuation of the cylinder-and-piston unit 57, the plate 51 displaces with the feeding arm 47 mounted thereon to the center of the bag. The feeding arm 47 is then pivoted by the cylinder-and-piston units 53 and 54 in a horizontal position. After this, the plate 51 by switching of the cylinder-and-piston unit 57 displaces outwardly transverse to the carriage pair 32. In this position the gripping plate 46 takes the bag and expands the opening. The cylinder-and-piston units 53 and 54 are then so actuated that the gripping plate 46 is pivoted so that the bag edge is located below the suction pipes 42 and 43. Since the gripping plate 46 is smaller than the bag opening, an insertion of the gripper plate 46 into the opened bag is guaranteed. The position of the gripping plate 46 required for taking the bag is shown in FIG. 7.
The weld seam located at the lower end of the bag is cooled on the way from the welding device to the opening station 5 by a cooling device 66 composed of blast nozzles 80. The carriage pair 32 displaces then by actuation of the cylinder-and-piston units 79 to its left end position. A reflecting light sensor 84 controls this position in order to have available a bag by the bag feeding device 45 for feeding to the filling pipe 81. When the bag is available, the reflecting light sensor 84 releases the working cycle of the filling pipe 81, and the filling pipe 81 lowers into the bag opening also in a known manner, and the bag is taken also in a known manner by jaws 82 and 83.
The gripping plate 46 is lifted by actuation of the cylinder-and-piston units 53 and 54 and displaces inwardly by actuation of the piston-and-cylinder unit 57. The carriage pair 32 displaces to its right position by actuation of the cylinder-and-piston unit 79. The bag after filling is placed on the conveyor transporting band driven in accordance with working pace of the machine. For adjusting the distance between the filling pipe 81 and the conveyor transporting band 9 in the event of a different dimension of the bag or a different filling volumes, the drive motor 70 is turned on within a short time.
After filling the bag, the grippers 58 and 59 brought on the carriage pair 32 take the bag 32 in a known manner. By actuating of the cylinder-and-piston unit 79, the carriage pair 32 again displaces to its left end position. Synchronously with the carriage pair 32, the conveyor transporting band 9 is driven for tranporting the filled bag to the welding device 8. The bag is provided in a known manner with a closing seam by the welding device 8. The welding devices 5 and 8 are advantageously identical. For service and in some cases repair work, the welding devices 5 and 8 may displace as a complete working unit on the angular rail 56. Thereby a good accessibility is guaranteed.
As can be seen from FIG. 3, the gripping plate 46 is provided with a central recess. It is thereby guaranteed that in the event of lateral fold bags, the lateral folds are not contacted during insertion of the gripping plate 46. As can be seen particularly from FIGS. 6 and 8, a lateral fold bag is provided with a rectangular filling opening. Thereby it is guaranteed that after filling of the bag, the lateral folds can be folded back to the initial position.
In the embodiments shown in FIGS. 1 and 3, the carriage pair 32 is provided with three stations. This results in that in the right end position of the carriage pair 32 a bag is taken from the welding device 5 via the grippers 36 and 37, simultaneously a bag is taken by the gripping plate 46 from the suction pipes 42 and 43, and also simultaneously a filled bag is taken by the grippers 58 and 59 from the filling pipe 81. In the left end position of the carriage pair 32, to the contrary, a bag is taken by the grippers 36 and 37 from the suction pipe 42 and 43, simultaneously a bag is taken from the jaws 82 and 83 by the gripping plate 46 and simultaneously a bag is taken from the welding device 8 by the grippers 58 and 59. Since the bags are displaced and taken by the grippers in correct positions to the individual working stations, a compact construction with accessible and reliable working cycle is guaranteed.
In the embodiment shown in FIG. 2, the gripper 65 arranged on the gripping chain 64 takes the bag separated from the loop foil web 2. The bottom weld seam is cooled during transporting toward the grippers 36 and 37 arranged on the carriage pair 32 by blasting nozzles 80 of the cooling device 66. Moreover, a further welding device 11 for closing the upper bag end is provided. The carriage pair 32 has then additional grippers 58' and 59'.
The welding device 8 is formed as a pre-welding device, whereas the welding device 11 is formed as a postwelding device and can be used as a corner welding device.
In this embodiment the carriage pair 32 is provided with four stations. It simultaneously performs four working steps. In this case a further welding device 12 is arranged after the welding device 5. It is possible to conduct a prewelding or corner welding. By the corner welding, a projecting bag corners are avoided, which are disturbing during transportation and palletizing.
The devices shown in FIGS. 6-11 are shown only for one machine side. The other machine side is mirror-symmetrical.
It will be understood that each of the elements described above, or two or more together, may also find a useful application in other types of constructions differing from the types described above.
While the invention has been illustrated and described as embodied in a machine for filling and closing bags of a synthetic plastic material, it is not intended to be limited to the details shown, since various modifications and structural changes may be made without departing in any way from the spirit of the present invention.
Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention. | A machine for filling and closing bags of a synthetic plastic material has a lowerable filling device, a transporting band spaced from the filling device and intermittently moveable in a longitudinal direction, opening, filling and welding stations, two carriages arranged in a space between the transporting band and the filling device at a distance corresponding to a band width and moveable synchronously with the transporting band parallel to the longitudinal direction, a feeding means on the carriages and having two feeding arms which are provided with gripping plates and move in the opening station from an upper position to a medium expanding position to be inserted into a bag mouth, and after expanding the bag the filling arms with the gripping plates move further in a direction transverse to the longitudinal direction to a lower transporting position, and two pairs of grippers arranged on the carriages at both sides of the feeding device to grip bags below their mouth edges, wherein one of the pairs of grippers is a front pair and arranged to bring an empty bag to the opening station, whereas the other of the pairs of grippers is a rear pair and arranged for bring a filled bag from the filling station to the welding station. | 1 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of patent application Ser. No. 10/395,360, filed Mar. 24, 2003, which is a continuation of patent application Ser. No. 09/417,372, filed Oct. 13, 1999, now U.S. Pat. No. 6,656,555.
FIELD OF THE INVENTION
[0002] This invention relates generally to printable forms and methods of making such forms and, more particularly, to printable forms with integrated labels and cards.
BACKGROUND OF THE INVENTION
[0003] There is a need for improved integrated business forms and methods of manufacturing such forms. Integrated forms consolidate different business objectives or services into a single form. A goal of such forms is not only to offer end users the flexibility to provide a variety of information and information transfer options through a single form, but to also reduce the time, money and material associated with using such business forms for both the end users and the form manufacturers. In the end, truly integrated forms increase the reliability, confidence and convenience in exchanging information between businesses and consumers.
[0004] The concept of an integrated form can be employed in numerous varieties depending on the objects of the particular end use. For example, an integrated form may consist of an invoice portion and a label portion incorporated into the same form. Thus, the business can print both the invoice information as well as the address information at the same time.
[0005] The mail order industry is a prime example of where such type of label is desired to ensure accurate billing and convenience to the consumer. For instance, in the mail order industry, the mail order company includes with the product an invoice, a shipping card addressed to the consumer and affixed to the packaging and a return card so that the consumer can conveniently return the purchased product within the return period. The obvious shortcoming with this process is the expense, time and possible confusion with purchasing, stocking and printing three separates pieces (i.e., the invoice, the addressee label, and the return address label or card).
[0006] An attempt to address these shortcomings is the use of a dedicated section on the invoice for printing of the return address. Thus, the form is sent through a printer which prints both the invoicing information and the return address in one process. In one form, the dedicated section may be outlined by a perforated section for detachment by the consumer. The obvious shortcomings include that the consumer must cut or tear the return address section from the form and affix it to the package with durable tape or adhesive in a manner that does not obstruct the address information. Because consumers do not always have adequate tape or adhesive, they use whatever they have available, which experience has shown, tends not to withstand the stresses associated with commercial shipping. As a result, the return address section is susceptible to falling off, which, when it occurs, often leads to disruption of the mailing system, disputes over whether the package was returned timely and damaged goods.
[0007] An attempt to address the return address situation has been made by adding a label to the form. These types of forms are commonly made by mating one side of a liner (such as a silicone coated liner) to the form and having a pressure sensitive label on the other side of the liner. The label then carries the address information, as well as the appropriate adhesive for reliable affixation to a return package. A shortcoming with this type of form is that the thickness created by the stacking of the form, the liner and the label often causes problems during the printing step. That is, the form jams the printer and prevents further use until appropriate service is undertaken. Another shortcoming is associated with pre-dispensing of the label because the label is not truly integrated with the form. That is, the label separates from the form and sticks to the rollers and/or drum of the printer. Thus, there is potential for serious damage to the printer. An even further shortcoming is the requirement additional materials to produce a three layer form, which is only capable of providing a limited number of labels on one side of the form.
[0008] Integrated forms also are desired in industries that have the need to distribute cards, such as membership cards for identification or other programs (e.g., frequent buyer programs and insurance programs). The cards traditionally have been printed separately and, to distribute such cards, they have been forwarded to the consumer under a separate forwarding cover letter. To address this situation, some companies attach the card to a form (such as a form forwarding letter) with a releasable adhesive. The obvious shortcoming is that the form is typically pre-printed and then run through a separate machine to add adhesive and the card. As a result, the card does not always become adequately affixed to the form, making it difficult to handle and susceptible to becoming unintentionally detached from the form. In addition, during removal of the card, it tends to peal off the top layer of the form, thereby reducing (and, in most cases eliminating) the backside of the card as a place for printed information.
[0009] Moreover, because the card tends to be inadequately secured to the form, it is not practical to consider printing after the card has been affixed. That is, the cards tend to fall off during the printing stage and bind up the printer. As explained above for labels, there is potential for serious damage to the printer. Thus, there is need for truly integrated forms that incorporate labels, cards, etc. into the form.
[0010] There also is the need to improve the methods of manufacturing such forms. The typical manufacturing equipment includes a paper infeed unit, a vacuum applicator unit, an unwind unit containing transfer tape, a hot melt applicator head, a feed control unit, an integral die cut unit, a hot melt unit and a fold-to-fold delivery unit. This processing equipment is commonly contained in two separate pieces of equipment. In other words, the manufacturing process is not one straight through in-line process, and therefore, tends to be expensive and labor intensive. The use of multiple machines slows the entire manufacturing process, increases costs and requires additional personnel.
[0011] Accordingly, it has been determined that there exist the need for an improved integrated form that is more end user friendly and that facilitates a more economical method of manufacturing.
SUMMARY OF THE INVENTION
[0012] In accordance with the invention, an improved integrated form is provided that enhances the use by end users and the manufacturing of such forms. In one form, there is provided an integrated from that includes a first printable substrate on one side of the form and a liner adjacent the first printable substrate. The liner has a first and second side. Adhesive on the first side of the liner maintains the first printable substrate to the first side of the liner in a manner that facilitates printing on the form without detachment of the first printable substrate. The first side of the liner is treated to permit a predetermined force to selectively remove the first printable substrate from the linear such that adhesive removes with the first printable substrate.
[0013] The first printable substrate may include a weakened line of substrate that defines at least in part a predetermined sized portion of substrate removable from the form. The weakened line of substrate resists unintentional detachment of the first printable substrate from the liner. The first printable substrate also may include a portion that extends beyond the liner.
[0014] The form may further include a second printable substrate on the other side of the form. The liner is intermediate the first and second printable substrates. Adhesive on the second side of liner maintains the second printable substrate to the second side of the liner in a manner that facilitates printing on the form without detachment of the second printable substrate. The second side of the liner being treated to permit a predetermined force to selectively remove the second printable substrate from the linear such that adhesive removes with the second printable substrate.
[0015] The second printable substrate also may include a weakened line of substrate that defines at least in part a predetermined sized portion of substrate removable from the form. The weakened line of substrate resists unintentional detachment of the second printable substrate from the liner.
[0016] The first printable substrate may also include a portion adjacent the removable portion of substrate that has been removed from the form to facilitate manual removal of the removable portion of substrate.
[0017] In another form, there is provided an integrated form that includes a printable substrate having a first side, a second side and a removable portion. A first layer of laminate covers at least a portion of one of the first and second sides of the printable substrate such that at least the removable portion of the printable substrate is covered. The first layer of laminate has a portion that is removable with the removable portion of the printable substrate. A second layer of laminate covers at least a portion of the first layer of laminate such that the second layer holds the removable portion of the substrate and first layer of laminate in the form while also allowing a predetermined force to remove the removable portion of the first layer of laminate and printable substrate from the form.
[0018] The integrated form may include a line of weakness extending through both the printable substrate and the first layer of laminate to define at least in part the removable portion of the printable substrate. The removable portion of the printable substrate also may have perimeter portion and the second layer of laminate may affix to the first layer of laminate only at the perimeter portion of the printable substrate. The form also may include a second portion of the printable substrate that is removable to facilitate removal of the other removable portion.
[0019] There also is provided a method of making an integrated form. The method includes the steps of providing a first printable substrate and providing a liner having a first and second side. Adhesive is applied to the first sides of the liner, and the first printable substrate is mated to the first side of the liner. Weakened lines of substrate in the first printable substrate are formed to define a label of predetermined size.
[0020] The method may include the steps of providing a second printable substrate, applying adhesive to the second side of the liner and mating the second printable substrate to the second side of the liner. Weakened lines of substrate may be formed in the second printable substrate to define a label of predetermined size.
[0021] The method also may include the steps of blocking the application of adhesive to a portion of the liner to be mated with the first printable substrate and removing a portion of the first printable substrate to facilitate easy removal of the label.
[0022] In another manner, there is provided a method of making an integrated form that includes the steps of providing a printable substrate having a first side and second side, applying a first layer of laminate to the second side of the printable substrate and applying a second layer of laminate to the first layer of laminate. Cut lines are formed through the printable substrate and the first layer of laminate to define a removable portion of the form being maintained in the form by the second layer of laminate until intentional removal from the form.
[0023] The method may include the step of removing a portion of the second layer of laminate across the removable portion of the printable substrate to reduce the amount a force necessary to remove the removable portion from the form. The method also may include cutting of a removable section of the form adjacent to the removable portion to facilitate removal of the removable portion.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] [0024]FIG. 1 is a top perspective view of an integrated label form embodying features in accordance with the present invention;
[0025] [0025]FIG. 2 is a bottom perspective view of the integrated form of FIG. 1;
[0026] [0026]FIG. 3 is a cross-section view taken along line 3 - 3 of the integrated form of FIG. 1;
[0027] [0027]FIG. 4 is an exploded perspective view of another embodiment of an integrated label form in accordance with the present invention;
[0028] [0028]FIG. 5 is a cross-sectional view taken along line 5 - 5 of the integrated from of FIG. 4 as assembled;
[0029] [0029]FIG. 6 is a cross-sectional view of an integrated form similar to that illustrated in FIG. 5 with the addition of multiple labels on one side;
[0030] [0030]FIG. 7 is a cross-sectional view of an integrated form similar to that illustrated in FIG. 6 with the addition of multiple labels on both sides;
[0031] [0031]FIG. 8 is a top perspective view of another embodiment of an integrated label form in accordance with the present invention;
[0032] [0032]FIG. 9 is a bottom perspective view of the integrated from of FIG. 8;
[0033] [0033]FIG. 10 is a cross-sectional view taken along line 10 - 10 of the integrated form of FIG. 8;
[0034] [0034]FIG. 11 is a top perspective view of an integrated card form embodying features in accordance with the present invention;
[0035] [0035]FIG. 12 is a top perspective view of the integrated card form of FIG. 11 with card removed;
[0036] [0036]FIG. 13 is a cross-sectional view taken along line 13 - 13 of the integrated card form of FIG. 11;
[0037] [0037]FIG. 14 is an exploded perspective view of the integrated card form of FIG. 11;
[0038] [0038]FIG. 15 is a exploded cross-sectional view taken along line 15 - 15 of the integrated card form of FIG. 14 with a corresponding cross-section of the card suspended above;
[0039] [0039]FIG. 16 is a top perspective view of another embodiment of an integrated card form embodying features in accordance with the present invention;
[0040] [0040]FIG. 17 is a bottom perspective view of the integrated card form of FIG. 16;
[0041] [0041]FIG. 18 is a cross-sectional view taken along line 18 - 18 of the integrated card form of FIG. 16;
[0042] [0042]FIG. 19 is an exploded perspective view of the integrated card form of FIG. 16;
[0043] [0043]FIG. 20 is a exploded cross-sectional view taken along line 20 - 20 of the integrated card form of FIG. 19 with a corresponding cross-section of the card suspended above;
[0044] [0044]FIG. 21 is a top perspective view of an integrated label form embodying features in accordance with the present invention;
[0045] [0045]FIG. 22 is a cross-section view taken along line 22 - 22 of the integrated form of FIG. 21;
[0046] [0046]FIG. 23 is a schematic view of an apparatus and materials for making a precut laminate;
[0047] [0047]FIG. 24 is a perspective view of materials being used in the apparatus of FIG. 23 to make the precut laminate;
[0048] [0048]FIG. 25 is a schematic view of an apparatus and materials for making business forms using the precut laminate made using the apparatus of FIG. 23; and
[0049] [0049]FIG. 26 is a perspective view of materials being used in the apparatus of FIG. 25 to make the business forms.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0050] Referring to FIGS. 1-3, there is illustrated a form 10 embodying the truly integrated label features of the present invention. The integrated form 10 facilities reliable printing by the end user and convenient labels for the end user as well as others (such as consumers).
[0051] The form 10 is composed of three substrate layers: a top printable substrate 12 ; an intermediate liner substrate 14 ; and a bottom printable substrate 16 . The top and bottom substrates 12 and 16 are made of material that is capable of being readily printed on using conventional printers, such as laser printers. Such materials include paper, card stock or even printable polymer based substrates.
[0052] The liner substrate 14 is mated to the top and bottom substrates 12 and 16 with a pressure sensitive adhesive 18 on both sides. The liner substrate 14 is made of material and treated such that it has reduced binding characteristics to allow a label portion 22 to be easily separated for use by the end user but that will not become detached during printing. Such liner material includes silicone coated glassine, on both sides, as well as Teflon® coated glassine, and bleachcraft may be substituted for glassine.
[0053] In manufacturing the form 10 , the top and bottom printable substrates 12 and 16 are mated to the liner substrate 14 by adhesive 18 . The adhesive 18 is hot melt adhesive or any other adhesive capable of releasably attaching the substrates 12 and 16 to liner substrate 14 . The form 10 is then sent through a die press to create weakened lines 20 on the top substrate 12 to define top labels 22 a and 22 b and on the bottom substrate 16 to define bottom label 22 c. As a result, dedicated sections of the printable substrates 12 and 16 become the labels 22 a and 22 b, thereby providing a form 10 with truly integrated labels.
[0054] Alternatively, the bottom side of liner 14 may already include the bottom printable substrate 16 , (a pre-labeled liner). In this case, adhesive 18 is applied to the side of the liner 14 not having the label 22 c, and mated to first printable substrate 12 . The combination of substrates is then taken through a die press where the first printable substrate is pressed creating labels 22 a and 22 b. Alternatively, the pre-labeled liner 14 may not have been die pressed as of yet thereby requiring the second printable substrate 16 to be die pressed as well.
[0055] As illustrated in FIG. 1, the top printable substrate 12 includes two labels 22 a and 22 b. The remainder 24 of the top substrate 12 is left to supply printed information that does not required transfer capability via a label. Hence, the liner 14 does not extend below portion 24 of the top substrate 12 . As an example, if the form 10 was an integrated label invoice form, section 24 would include the order information 22 , label 22 a would be the shipping label, label 22 b would be the return shipping label and label 22 c would be an additional label for other purposes. Thus, the form 10 only consumes the minimal amount of material necessary to provide the required form space and number of labels.
[0056] Where additional labels are required because more of the information on the form must be transferred, an alternate form 26 is constructed in which a larger liner substrate is incorporated into the form. Referring to FIGS. 4-7, the form 26 includes a liner substrate 28 and/or a bottom printable substrate 30 that extends over as much of the top printable substrate 32 as is necessary to provide the desired number and size of labels. As a result, the cost of supplying additional labels to transfer more information is reduced because labels are formed on both sides of the liner substrate 28 with the top substrate 32 and the bottom substrate 30 .
[0057] More specifically, as illustrated, the liner substrate 28 and the bottom substrate 30 are sized such that their edges are co-extensive with the top substrate 32 . The liner substrate 26 is intermediate the top substrate 32 and the bottom substrate 30 , and is affixed to such substrates with an adhesive 34 . As illustrated in FIG. 5, the bottom and top substrates 30 and 32 each constitute one large label. As illustrated in FIG. 6, the top substrate 32 constitutes one large label, and the bottom substrate 30 is die cut to include cut lines 36 that define a number of labels 38 . As illustrated in FIG. 7, the top substrate 32 also is die cut to include cut lines 36 which define a number of labels 40 . The material for the top and bottom substrates ( 32 and 30 ), the liner 26 and the adhesive 34 is the same as that described above for form 10 of FIGS. 1-3.
[0058] Referring to FIGS. 8-10, an integrated label form 42 in accordance with another aspect of the invention is shown. The form 42 includes a printable substrate 44 and a liner substrate 46 . With form 42 , the liner substrate 46 does not include any indentations or deformations as a result of die cutting to form the labels because the printable substrate 44 is die pressed before being mated to the liner substrate 46 . By die pressing printable substrate 44 prior to mating it with liner substrate 46 , the liner substrate 46 is not exposed to any possibility of being weakened or deformed due to the die cutting process. This ensures that the liner substrate 46 will be as smooth and uniform as possible, and increases the likelihood that the integrated form 42 will print properly.
[0059] More specifically, the printable substrate 44 is affixed to the liner substrate 46 by adhesive 48 . Prior to affixing these substrates, the printable substrate 44 is die pressed to form lines of weakness 50 (or perforations) that define a number of labels 52 . As illustrated with label 52 a, one can easily peal the labels from the liner substrate 46 along the lines of weakness 50 . The adhesive 48 lifts off the liner substrate 46 and remains with the label 52 a so that it can be transferred and affixed to another surface.
[0060] To manufacture this form 42 , the printable substrate 44 is printed with the desired graphics and/or text and is then die pressed to designated the labels 52 with the appropriate lines of weakness 50 . Finally, the printed substrate 44 is mated to the liner with the adhesive 48 .
[0061] Referring to FIGS. 11-15, there is illustrated an integrated card form 54 embodying features of the present invention. The form 54 includes a printable substrate 56 from which is formed a card 58 . The printable substrate 56 has a top side 60 and a bottom side 62 upon which both sides can be printed any desired graphics and/or text.
[0062] The bottom side 62 is covered with a first layer of laminate 64 over the card portion 58 . The first layer of laminate 64 provides rigidity and protection to the card 58 . A second layer of laminate 66 is affixed to the first layer 64 to hold the card 58 in place in the form. Both layers of laminate include a layer of adhesive 68 on one side for affixation to the substrate 56 and the other layer of laminate 64 .
[0063] The card 58 is defined by a number of lines of weakness or cuts 70 die cut through the substrate 56 and the first layer of laminate 64 . The second layer of laminate 66 includes an aperture 72 at the card 58 which is defined by a ledge 74 that extends inward beyond the cuts 70 to expose the adhesive 68 to secure the card 58 in place. The ledge may have a width of ⅛th of an inch width.
[0064] In other words, the card 58 rests against the ledge 74 and the adhesive 68 at the ledge 74 affixes to the first layer of laminate 74 about the perimeter portion of the card 58 in a manner that prevents unintentional release of the card 58 while also allowing the card 58 to be intentionally removed. For instance, to remove the card 58 , one can easily press from the backside of the card 58 to push the card from the form 54 . The size of the ledge 74 and the amount and type of adhesive 68 is coordinated to provide the appropriate gripping action on the card 58 .
[0065] Alternatively, the second layer of laminate may not have an aperture, but may act as a transparent window exposing the bottom of the card. In this instance, it is preferred that the entire window area not be covered completely with adhesive to facilitate removal of the card.
[0066] To manufacture the integrated card form 54 , the top side 60 and bottom side 62 of card 58 are printed with graphics and text as desired. Next, the first layer of laminate 64 is mated with the back side of substrate 56 and then the second layer of laminate 66 . The lines of weakened substrate or cuts 70 are die cut from the top side 60 of the substrate 56 through the first layer of laminate 64 to form the card 58 . The second layer of laminate 66 is not cut so that it can hold the card 58 in the form 54 against unintentional detachment. Alternatively, the second layer of laminate 66 may be cut to remove a portion at the card and to form the ledge 74 . This is performed prior to mating the second layer of laminate 66 with the first layer of laminate 64 . The entire process is to be done on a single machine. Feed structure 76 is provided to aid with feeding the integrated form through a printer (not shown). However in alternate embodiments no feed structure 76 may be provided.
[0067] To further assist in card removal, the form 54 also includes a recess 78 adjacent the card 58 for one to insert a finger, thumb, or part thereof to facilitate removal. The recess extends through the printable substrate 56 and both the layers of laminate 64 and 66 . Recess 78 could be used in a similar manner in integrated form 10 (FIGS. 1-3), form 26 (FIGS. 4-7), and form 42 (FIGS. 8-10). That is, a portion of the substrate could be die cut prior to being mated with the liner and the liner could be blocked from receiving adhesive at that section. As a result, a portion of the liner is exposed and one can easily peel the label from the liner to separate it from the form.
[0068] Turning now to a variation on the business form 54 having an integrated removable card 58 as discussed above with respect to FIGS. 11-15, a business form 154 is provided having a removable integrated card 158 attached by gaps between perforations 170 . The business form 154 is constructed using a base layer 156 and a liner layer 164 , as disclosed in FIGS. 16-20. The base layer 156 is attached on one of its sides to the liner layer 164 using adhesive 168 . The integrated removable card 158 comprises at least a portion of the base layer 156 and the liner layer 164 of the business form 154 . By using only two layers, the base and liner layers 156 and 164 , to generally produce the form 154 , the amount of material used in producing the form 154 , and thus the cost of the form 154 , can be reduced as compared to having more than two layers. However, other layers, such as the cover layer discussed below, may also be combined with the base and liner layers 156 and 164 of the form 154 .
[0069] The card 158 has a periphery edge substantially defined by a plurality of die cuts 170 extending substantially through both the base and liner layers 156 and 164 . The plurality of die cuts or perforations 170 and gaps therebetween form a perforated periphery of the card 158 . The perforated periphery of the integrated removable card 158 allows for the card 158 to readily be removable from the business form 154 , while also maintaining the card 158 in the business form 154 and protecting against unintentional removal. To this end, the perforations 170 are spaced apart a sufficient distance from adjacent perforations 170 in order to have a plurality of bridging portions 179 disposed therebetween to assist in maintaining the card 158 in the form 154 against unintentional removal from the form 154 .
[0070] An optional cut-out 178 is positioned adjacent the periphery of the card 158 to assist in removal of the card 158 from the form 154 . The cut-out 178 preferably extends through both the base and liner layers 156 and 164 of the integrated business form 154 . Feed holes 176 optionally may be positioned on opposing longitudinal edges of the form 154 .
[0071] The base layer 156 is generally rectangular and the liner layer 164 extends generally along the entirety of at least one of the dimensions of the base layer 156 , as illustrated in FIGS. 16-20. As shown in FIG. 17, however, the liner layer 164 need not completely cover the base layer 156 .
[0072] The base layer 156 has a printable first side 160 and an opposing printable second side 162 . Preferably, the base layer 156 may be printed, either before or after construction of the business form 154 , such as by using either a printing press or a typical office or home printer. The base layer 156 may be formed of a cardstock material and the liner layer 164 may be formed of a transparent film. Forming the liner layer 164 of a transparent film allows for any printing or other indicia on the second side 162 of the base layer 156 to be visible through the liner layer 164 . Unprinted space capable of receiving printed indicia may also be provided on the first side 160 of the card 158 .
[0073] A cover layer may be adhesively attached to the first side 160 of the base layer 156 opposite the liner layer 164 . The cover layer may be at least partially transparent, permitting printing or other indicia on the first side 160 of the base layer 156 to be visible through the cover layer. When the cover layer and liner layer 164 are both used on the business form 154 , additional stiffness of the removable card portion 158 can be achieved. The cover layer or liner layer 164 may comprise materials selected to allow for printing of indicia thereon.
[0074] A method is also provided of making a business form 154 having an integrated removable card portion 158 , such as the form illustrated in FIGS. 16-20. The method includes providing a base layer 156 having a first side 160 and an opposing second side 162 . A liner layer 164 is secured using adhesive 168 to at least a portion of the second side 162 of the base layer 156 . Printing on both the first and second sides 160 and 162 of the base layer 156 may occur prior to attachment of the liner layer 164 , and/or the first side 160 of the base layer 156 may be printed after attachment of the liner layer 164 . Printing may also be placed on the liner layer 164 . After the liner layer 164 is secured to the base layer 156 , a plurality of spaced die cuts 170 extending substantially through the base and liner layers 156 and 164 are formed. Bridging portions 179 disposed between adjacent die cuts 170 remain to connect the card 158 and the form 156 so that the card 158 is maintained in the form 156 against unintentional removal therefrom. A cut-out 178 is cut through the base and liner layers 156 and 164 adjacent the periphery of the card 158 to facilitate removal of the card 158 from the form 156 .
[0075] A business form 210 having removable integrated portions 222 a and 222 b, similar to the removal integrated portions 22 a and 22 b discussed above with respect to FIGS. 1-3, is provided having an integrated tab 225 , as shown in FIGS. 21 and 22. The integrated tab 225 is provided in one or both of the removal integrated portions 222 a and 222 b of the business form 210 . One or both of the removable integrated portions 222 a and 222 b of the form 210 may be removed and, for example, adhered onto an object, such as an envelope or a package. The integrated tab 225 of the removable integrated portion 222 b can be at least partially removed to expose a previously hidden or covered portion of a liner layer 214 of the removable integrated label portion 222 b, as shown in FIG. 21.
[0076] The business form comprises a base layer 224 , the liner layer 214 , and a backing layer 216 , as shown in FIG. 22. The liner layer 214 is secured using adhesive 218 a to at least a portion of the base layer 224 . The backing layer 216 is secured using adhesive 218 b to at least a portion of the liner layer 214 on a side of the liner layer 214 opposite the base layer 224 .
[0077] A top printable substrate 212 includes two regions 221 and 224 , a region 221 having the integrated removable portions 222 a and 222 b and a region 224 lacking the integrated removable portions, as illustrated in FIG. 21. As illustrated, the remainder region 224 of the top substrate 212 does not have integrated removable portions 222 a and 222 b. The liner and backing layers 214 and 216 are only positioned below the region 21 of the top substrate 212 . Thus, the form 210 may only consume the minimal amount of material necessary to provide the required form space and number of labels. However, the entire form 210 may have integrated removable portions and, therefore, the liner and backing layers 214 and 216 extending under the base layer 224 . Although the business form 210 is described and depicted in FIGS. 21 and 22 as having two integrated removable portions 222 a and 222 b, one of which has an integrated tab 225 , multiple integrated portions may be provided on the business form and one or more tabs may be provided on each integrated removable portion.
[0078] The integrated removable label portion 222 a and 222 b of the form 210 comprises at least a portion of the base layer 224 and the liner layer 214 . The integrated removable portion has a periphery edge substantially defined by a first die cut 220 extending substantially through the base and liner layers 224 and 214 so that the backing layer 216 maintains the integrated removable portion 222 a or 222 b in the form 210 against unintentional removal from the form 210 . To remove the integrated removable portion 222 a or 222 b from the form 210 , the portion 222 a or 222 b, comprising the base layer 224 and the liner layer 214 , is separated from the backing layer 216 . A cut-out 278 may be positioned adjacent the integrated removable portion 222 a or 222 b and may extend through the base, liner and backing layers 224 , 214 and 216 to assist in removal of the integrated removable portion 222 a or 222 b from the form 210 .
[0079] The side of the backing layer 216 adjacent the liner layer 214 may have a lesser affinity for the adhesive 218 b than the adjacent side of the liner layer 214 , thereby allowing the adhesive 218 b , once the integrated removable portion 222 a or 222 b of the form 210 is removed, to remain on the side of the liner layer 214 opposite the base layer 224 . Thus, the integrated removable portion 222 a or 222 b comprises a label that can be adhered to an object. Alternatively, the side of the backing layer 216 adjacent the liner layer 214 may have a greater affinity for the adhesive 218 b than the adjacent side of the liner layer 214 , thereby allowing the adhesive 218 b , once the integrated removable portion 222 a or 222 b of the form 210 is removed, to remain on the side of the backing layer 216 . In this aspect, the integrated removable portion 222 a or 222 b may comprise a card.
[0080] The integrated tab 225 may be opened either before or after removal of the integrated removable portion 222 b from the form 210 . The integrated tab 225 comprises a portion of the base layer 224 and is coextensive with the integrated removable portion 222 b . The integrated tab 225 is at least partially removable from the base layer 224 . A periphery edge of the integrated tab is generally defined by a plurality of die cuts 223 extending substantially through the base layer 224 so that the liner layer 214 at least partially maintains the integrated tab 225 in the integrated removable portion 222 b against unintentional removal from the portion 222 b.
[0081] The integrated tab 225 can be lifted to expose a portion of the liner layer 214 . The integrated tab 225 may be at least partially hinged to the base layer 224 , such as by an uncut portion or partially uncut portion 223 ′ extending therebetween, as illustrated in FIG. 21. Alternatively, the integrated tab 225 may be completely removable from the removable integrated portion 222 b . A cut-out 279 may extend through the base and liner layers 224 and 214 of the integrated removable portion 222 b and may be positioned adjacent the periphery edge of the tab 225 to allow the tab 225 to be readily removed from the integrated removable portion 222 b.
[0082] The base layer 224 may have a lesser affinity for retaining the adhesive 218 a than the adjacent side of the tab 225 , thereby allowing the tab 225 to be removed from the removable integrated portion 222 b and adhered to an object. Alternatively, the base layer 224 may have a greater affinity for retaining the adhesive 218 a than the adjacent side of the tab, thereby allowing the adhesive 218 a to remain on the removable integrated portion 222 b , as opposed to on the adjacent side of the tab 225 , after removal of the tab 225 .
[0083] Various combinations of printing on different locations of the form 210 can be used to customize usage of the form 210 . To facilitate such uses, any or all of the components, such as the base, liner and backing layers 224 , 214 and 216 may comprise materials suitable for being printed upon. For example, the form 210 may comprise an invoice for an item receivable via shipping. As an example, region 224 could include the order information, label 222 a could be the shipping label, and label 222 b could be the return shipping label. A barcode or other information may be printed on the portion of liner layer 214 beneath the integrated tab 225 such that when the integrated tab 225 is lifted or removed, the information is exposed. Alternatively or in addition, information may be printed on one or both sides of the integrated tab 225 . Thus use of the tab 225 allows for the selective display or access to the printing on the side of the tab 225 adjacent the liner layer 214 or on the portion of the liner layer 214 disposed beneath the tab 225 and visible once the tab 225 is opened or removed.
[0084] A method of making the business form 210 having the integrated removable portions 222 a and 222 b and the tab 225 includes providing the base layer 224 , using the adhesive 218 a to secure the liner layer 214 to at least a portion of the base layer 214 , and using the adhesive 218 b to secure the backing layer 216 to the liner layer 214 . A plurality of first die cuts 220 extending substantially through the base and liner layers 224 and 214 are made to define the periphery edges of the integrated removable portions 222 a and 222 b . A plurality of second die cuts 223 are made extending substantially through the base layer 224 and coextensive with the integrated removable portion 222 b substantially define the periphery edges of the integrated tab 225 .
[0085] Business forms, such as those described above with respect to FIGS. 11-15, may be made in a process using a precut laminate 380 in one or more form manufacturing apparatus, as illustrated in FIGS. 23-26. The precut laminate 380 may comprise a backing layer 364 secured using adhesive 368 to a liner layer 366 , as illustrated in FIG. 24. The precut laminate 380 has an integrated removable card portion 374 defined by a plurality of die cuts. The integrated removable card portion 374 can be left in the precut laminate 380 . Alternative, and as illustrated in the card of FIGS. 11-15, the removable card portion 374 can be punched out and removed from the precut laminate 380 . The die cuts are substantially through the the backing layer 364 but not completely through the liner layer 366 , thereby allowing the integrated removable card portion 374 of the backing layer 364 to be supported by the liner layer 366 .
[0086] After formation of the precut laminate, a base layer 360 is attached to the precut laminate 380 , such as by using adhesive 369 . A plurality of die cuts are formed substantially through the base and liner layers 380 and 366 in order to define an integrated removable card 370 . The die cuts at least partially surround the integrated removable card portion 374 of the backing layer 364 so that the backing layer 364 maintains the card 370 in the form against unintentional removable from the form. A cut-out may be positioned adjacent the periphery of the card 370 and through the base, liner and backing layers 360 , 366 and 364 in order to facilitate removal of the integrated card 370 from the form.
[0087] The apparatus used to produce the pre-cut laminate 380 receives the backing and liner layers 364 and 366 , for example, in roll form, as illustrated in FIG. 23. The backing layer 364 is unwound and the adhesive 368 is applied thereto using an adhesive application station 368 a. The liner layer 366 is also unwound, and is directed onto the adhesive 368 applied to the backing layer 364 in order to mate the backing and liner layers 364 and 366 . Alternatively, the adhesive 368 may be applied to the liner layer 366 and the backing layer 364 mated therewith. After the adhesive 368 is applied and the backing and liner layers 364 and 366 are mated, a die cut station 374 a makes the die cuts substantially through the backing layer 364 to define the integrated removable card portion 374 of the backing layer 364 .
[0088] After die cutting, the precut laminate 380 is converted to in a dispensing configuration. The dispensing configuration is adapted to allow the precut laminate 380 to be attached using adhesive 369 to the base layer 360 . For example, the dispensing configuration of the precut laminate 380 may be a roll which would allow the precut laminate 380 to be unwound into a generally planer feed configuration for feeding through the apparatus used to attach the base layer 360 to the precut laminate 380 , as illustrated in FIG. 26. Another example of a dispensing configuration is a fan-folded configuration. For example, the fan-folding configuration may comprise one or more integrated removable card portions 374 in sheets that are folded relative to each other. The sheets of adjacent fan-folded stacks may be connected to allow for the continuous use of stacks of precut laminate 380 without having to stop the apparatus.
[0089] The apparatus used to produce the business form receives the pre-cut laminate 380 and the base layer 360 , for example, in roll form, as illustrated in FIG. 25. The pre-cut laminate 380 is unwound and the adhesive 369 is applied to the liner layer 366 using an adhesive application station 369 a. The base layer 360 is also unwound, and is directed onto the adhesive 369 applied to the liner layer 366 in order to mate the pre-cut laminate 380 and the base layer 360 . Alternatively, the adhesive 369 may be applied to the base layer 360 and the pre-cut laminate 380 mated therewith. After the adhesive 369 is applied and the pre-cut laminate 380 and base layer 360 are mated, a die cut station 370 a makes the die cuts substantially through the backing layer 364 to define the integrated removable card 370 . A cut-out for assisting in removal of the card 370 from the form may be made through the backing, liner and base layers 364 , 366 and 360 and positioned adjacent the card 370 using a punching station 378 . After manufacture of the forms, the forms may be provided in an output configuration, such as by winding into a roll 390 , fan-folding, sheeting or the like.
[0090] Printing 367 may be placed on the business form and the components thereof at various stages, such as illustrated in FIG. 25. For example, printing may be placed upon the top and bottom sides of the base layer 360 using printing stations 367 a and 367 b. Printing may also be placed on the backing layer 364 of the pre-cut laminate 380 using a printing station 367 c.
[0091] The use of the pre-cut laminate 380 allows for business forms having integrated removable cards or labels 370 to be produced in a multi-step process. For example, a single apparatus may be configured to produce the pre-cut laminate, and then used to produce the business forms by combining the pre-cut laminate 380 with the base layer 360 . This allows for a single machine, having a smaller size and requiring fewer die cut, printing, and adhesive stations, to produce the business forms. Alternatively, the pre-cut laminate 380 may be produced on a different apparatus than that used to combine the pre-cut laminate 380 with the base layer 360 . For example, the pre-cut laminate 380 may be made off-site and delivered to the location of the apparatus for combination with the base layer 360 .
[0092] While there have been illustrated and described particular embodiments of the present invention, it will be appreciated that numerous changes and modifications will occur to those skilled in the art, and it is intended in the appended claims to cover all those changes and modifications which fall within the true spirit and scope of the present invention. | A form that incorporates either a label or card such that the form can be reliably printed on by the end user and manufactured less expensively. The integrated label form includes a top printable substrate and a liner substrate mated together by an adhesive. The top printable substrate serves at least partially as removable portions capable of being reapplied. Weakened lines of substrate may be provided to define removable portions on the top printable substrate. The form also may include a similar printable substrate mated to the other side of the liner by adhesive. Weakened lines of substrate also may formed in the second substrate to define removable portions. The integrated card form includes a printable substrate and a first and second laminate mated to the substrate and together by an adhesive. Weakened lines of substrate and first laminate define an integrated removable portion capable of being held in the form by the second laminate and easily removed manually when desired. In the integrated card form and the integrated label form, a recess may be provided adjacent the removable portion to facilitate removal of the removable portion. The integrated forms are easily manufactured by a single piece of equipment. | 1 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a Division of copending application Ser. No. 12/412,738 filed Mar. 27, 2009, the contents of which are hereby incorporated by reference in its entirety.
FIELD OF THE INVENTION
[0002] This invention generally relates to a hydrocarbon conversion system, and more particularly to at least one of a process, a catalyst composition, and/or a slurry catalyst system relating thereto.
DESCRIPTION OF THE RELATED ART
[0003] Catalysts are often used in hydroconversion processes. In the hydroconversion of heavy oils, biofuels, and coal liquids, typically a catalytic slurry system is utilized. In such systems, often large amounts of catalyst are utilized.
[0004] Typically, these catalysts are relatively inexpensive and do not contain valuable metals, such as noble group VIII metals. Often, such catalysts have a uniform, small particle size. Unfortunately, catalyst, such as iron sulfate, can meet the desired economic costs, but may also be hydrophilic. As such, the catalytic material may absorb moisture and clump. Generally, the clumping of the catalyst creates problems when attempting to disperse the catalyst into the hydrocarbon feed. Usually, the catalyst is dispersed into a hydrocarbon feed to form a slurry before the combined material enters a reactor. Thus, a catalyst material with a high degree of flowability is desirable. Typically, a catalyst that can be relatively hydrophobic and clumping resistant would have the requisite flowability.
SUMMARY OF THE INVENTION
[0005] One exemplary embodiment can be a process for making a catalyst including an effective amount of iron for catalyzing one or more reactions in a hydrocarbon conversion system. The process can include grinding and coating the particles. The ground particles can have an effective amount of iron, and substantially all the particles may have a maximum dimension no larger than about 130 microns. The coating can have an effective amount of one or more hydrocarbons to provide the catalyst with improved flowability.
[0006] Another exemplary embodiment may be a slurry catalyst composition. The slurry catalyst composition can have a catalytically effective amount of one or more compounds including iron, and a coating including one or more hydrocarbons having a melting point temperature of no more than about 250° C.
[0007] Yet a further exemplary embodiment can be a slurry catalyst system. The slurry catalyst system may include an upflow tubular reactor. Generally, the upflow tubular reactor can receive a hydrocarbon feed and a slurry catalyst composition. The hydrocarbon feed can include one or more compounds having an initial boiling point temperature of at least about 340° C. The slurry catalyst composition may include a catalytically effective amount of one or more compounds, and a coating having a hydrocarbon with a melting point temperature of no more than about 250° C. for improving flowability of the slurry catalyst composition.
[0008] The embodiments disclosed herein can provide a slurry catalyst material that can be hydrophobic and resist clumping. As a result, the material can be easily handled and combined with a hydrocarbon feed to form a slurry before entering a hydroconversion reactor. The advantageous properties allow the use of a relatively inexpensive material that can be easily handled to facilitate forming a slurry for conducting hydroprocessing reactions.
DEFINITIONS
[0009] As used herein, the term “stream” can be a stream including various hydrocarbon molecules, such as straight-chain, branched, or cyclic alkanes, alkenes, alkadienes, and alkynes, and optionally other substances, such as gases, e.g., hydrogen, or impurities, such as heavy metals, and sulfur and nitrogen compounds. The stream can also include aromatic and non-aromatic hydrocarbons. Moreover, the hydrocarbon molecules may be abbreviated C 1 , C 2 , C 3 . . . C n where “n” represents the number of carbon atoms in the one or more hydrocarbon molecules.
[0010] As used herein, the term “zone” can refer to an area including one or more equipment items and/or one or more sub-zones. Equipment items can include one or more reactors or reactor vessels, heaters, exchangers, pipes, pumps, compressors, and controllers. Additionally, an equipment item, such as a reactor, dryer, or vessel, can further include one or more zones or sub-zones.
[0011] As used herein, the term “substantially” can mean an amount of generally at least about 80%, preferably about 90%, and optimally about 99%, by weight, of a compound, class of compounds, or catalyst.
BRIEF DESCRIPTION OF THE DRAWING
[0012] The FIGURE is a schematic depiction of an exemplary hydrocarbon conversion system.
DETAILED DESCRIPTION
[0013] Referring to the FIGURE, one exemplary hydrocarbon conversion system 100 can be a slurry reaction or bubble column system including a reservoir 120 , a holding tank 130 , a heater 140 , and a hydroprocessing reaction zone 150 . Exemplary systems are disclosed in, e.g., U.S. Pat. No. 5,755,955 and U.S. Pat. No. 5,474,977.
[0014] Typically, a hydrocarbon feed 104 can be provided, which may be a heavy oil vacuum bottom, a vacuum residue, a fluid catalytic cracking slurry oil or other heavy hydrocarbon-derived oils. Alternatively, the hydrocarbon feed 104 can be at least one of coal liquid or a biofuel feedstock such as lignin, one or more plant parts, one or more fruits, one or more vegetables, a plant processing waste, one or more woodchips, chaff, one or more grains, one or more grasses, a corn, one or more corn husks, one or more weeds, one or more aquatic plants, hay, paper, and any cellulose-containing biological material.
[0015] A reservoir 120 can provide a catalyst to be combined with the hydrocarbon feed 104 . A resultant slurry 108 , i.e., a combination of the catalyst and the hydrocarbon feed 104 having a solids content of about 0.01 to about 10%, by weight, can pass to a holding tank 130 before being combined with a gas 112 .
[0016] The gas 112 typically contains hydrogen, which can be once-through hydrogen optionally with no significant amount of recycled gases. Alternatively, the gas 112 can contain recycled hydrogen gas optionally with added hydrogen as the hydrogen is consumed during the one or more hydroprocessing reactions. The gas 112 may be essentially pure hydrogen or may include additives such as hydrogen sulfide or light hydrocarbons, e.g., methane and ethane. Reactive or non-reactive gases may be combined with the hydrogen introduced into the hydroprocessing reaction zone 150 at the desired pressure to achieve the desired product yields.
[0017] A combined feed 116 including the slurry 108 and the gas 112 can enter the heater 140 . Typically, the heater 140 is a heat exchanger using any suitable fluid such as the hydroprocessing reaction zone 150 effluent or high pressure steam to provide the requisite heating requirement. Afterwards, the heated combined feed 116 can enter the hydroprocessing reaction zone 150 including an upload tubular reactor 160 . Often, slurry hydroprocessing is carried out using reactor conditions sufficient to crack at least a portion of the hydrocarbon feed 104 to lower boiling products, such as one or more distillate hydrocarbons, naphtha, and/or C1 to C4 products. Conditions in the hydroprocessing reaction zone 150 can include a temperature of about 340° to about 600° C., a hydrogen partial pressure of about 3.5 to about 10.5 MPa and a space velocity of about 0.1 to about 30 volumes of hydrocarbon feed 104 per hour per reactor or reaction zone volume. A reaction product 170 can exit the hydroprocessing reaction zone 150 .
[0018] Generally, the catalyst for the hydrocarbon conversion system 100 provides a composition that is hydrophobic and resists clumping. Consequently, it may be suitable and easily combined with the hydrocarbon feed 104 . Typically, the slurry catalyst composition can include a catalytically effective amount of one or more compounds having iron. Particularly, the one or more compounds can include at least one of an iron oxide, an iron sulfate, and an iron carbonate. Other forms of iron can include at least one of an iron sulfide, a pyrrhotite, and a pyrite. What is more, the catalyst can contain materials other than an iron, such as at least one of molybdenum, nickel, and manganese, and/or a salt, an oxide, and/or a mineral thereof.
[0019] Preferably, the one or more compounds includes an iron sulfate, and more preferably at least one of an iron sulfate monohydrate and an iron sulfate heptahydrate. Oxidic iron-containing compounds obtained from sources such as a limonite, a laterite, a wrought iron, a clay, a magnetite, a hematite, a gibbsite, or a Kisch iron can also be used. One particularly desired material is ferrous sulfate. The ferrous sulfate can either be a monohydrate or a heptahydrate. The monohydrate can contain up to about 15%, by weight, water while the heptahydrate can contain up to about 51%, by weight, water. The grain size of the particles can have a largest dimension greater than about 0.2 millimeter (hereinafter may be abbreviated “mm”) but smaller than about 4.3 mm as determined by about 95% of the particles. In addition, the bulk density can range from about 880 to about 1,200 kg per meter-cubed.
[0020] The ferrous sulfate can contain less than 1%, by weight, of one or more of the following, namely arsenic, cadmium, chromium, copper, lead, magnesium, manganese, nickel, and/or zinc. The ferrous sulfate can be obtained from any suitable source, such as QC Corporation of Baltimore, Md.
[0021] Typically, the catalyst particle coating can reduce the hydrophilic properties of the particles. The catalyst can include a coating of a hydrocarbon having an initial boiling point temperature of at least about 250° C., or about 340° C., and/or a melting point temperature of no more than about 250° C., or no more than about 80° C. In addition, the coating can include one or more hydrocarbons compatible with the feed for processing in a hydrocarbon conversion system, such as a fluid catalytic cracking slurry system. In addition, the coating can have sufficient moisture resistance to prevent agglomeration of the pelletized catalyst particles. Typically, the coating can include at least one of a wax, a pitch, a deasphalted oil, a petroleum resin, and a low molecular weight polymer.
[0022] Preferably, the coating can include a pitch having a melting point no more than about 250° C., preferably no more than about 225° C., or a paraffin wax having a melting point of no more than about 80° C., preferably no more than about 60° C.
[0023] Preparing an exemplary catalyst can include providing a weight ratio of catalyst to hydrocarbon coating of about 200:1 to about 1:1, optimally about 2:1. As an example, the catalyst coating can be about 0.5 to about 50%, by weight, of the total catalyst composition. A catalyst such as ferrous sulfate may contain water, which can include lattice bond water of hydration and/or physically absorbed water. A loss on ignition adjustment can be used to calculate the amount of catalyst to be combined with the hydrocarbon coating. The loss on adjustment may be made by measuring a weight loss on heating to about 600° C., and comparing the results with the theoretical value calculated based on the molecular formula to obtain an adjusted molecular weight for use in calculating the amounts to blend in the formulations.
[0024] The hydrocarbon coating, such as a pitch or a paraffin wax, can be combined with the catalyst, such as iron sulfate, e.g., iron sulfate monohydrate, in a continuous high speed mixer/heat exchanger. Optionally, a small amount of water, such as less than about 1%, by weight, based on the weight of the catalyst particles, can be added to aid in agglomerating the particles. The rotary shaft of the mixer can be equipped with paddles, which may atomize the mixture and convey it through the reaction chamber of the machine. The jacketed barrel and the rotary shaft may be heated by steam or an oil-based heating medium above the melting temperature of the hydrocarbon coating, such as about 50° C. above the melting point of the hydrocarbon coating. The hydrocarbon coating may be picked-up by the melted matrix as it is atomized by the rotation of the rotary shaft, which typically rotates at about 3,000 to about 4,000 revolutions per minute (hereinafter may be abbreviated “rpm”). Generally, a residence time is about 10 to about 20 seconds when the temperature of the jacket and the rotary shaft are above the melting point of the hydrocarbon coating. An exemplary mixer is sold under the trade designation TURBULIZER® made by Hosokawa Bepex Corporation of Minneapolis, Minn.
[0025] After leaving the mixer, the mixture can be cooled below the melting point of the coating. The produced catalyst particles can have a maximum dimension of about 50 to about 5,000 microns, preferably about 50 to 500 microns, more preferably less than about 130 microns, and optimally less than about 90 microns. The catalyst particles may be agglomerated into larger spheres of about 1 centimeter in diameter that can easily be handled. The ferrous sulfate can be pelletized by using other methods, such as those methods disclosed in, e.g., U.S. Pat. No. 5,108,481.
[0026] Desirably, the dispersability of the catalyst in the hydrocarbon by using the hydrocarbon coating may prevent agglomeration when storing and handling the catalyst, and thus aides mixing and dispersing into a hydrocarbon feed. As an example, the catalyst can contain a core of monohydrate or moist heptahydrate with a coating of pitch. The catalyst can have a consistent iron concentration delivered to a hydroconversion system in a dry, hydrophobic, and free-flowing large particles. Thus, the catalyst can be easily crumbled and dissolved in a hot feed with, e.g., a roll crusher and screen, with a minimum of mess and no moisture pick-up, and hence, typically, without milling equipment.
ILLUSTRATIVE EMBODIMENTS
[0027] The following examples are intended to further illustrate the subject particle(s). These illustrative embodiments of the invention are not meant to limit the claims of this invention to the particular details of these examples. These examples can be based on engineering calculations and actual operating experience with similar processes.
Example 1
[0028] About 30 grams of paraffin wax is melted at about 60° C. in a flask equipped with a mixer, such as a mixer sold under the trade designation L4RT by Silverson Machines, Inc. of East Longmeadow, Mass. The temperature is increased until the viscosity is reduced enough to allow thorough mixing at about 100° C. While stirring, about 60 grams of the iron sulfate monohydrate is added. The iron sulfate monohydrate can have a bulk density of 1.9 g/cc and a crystal density of 3.0 g/cc with a voidage of about 36.7%. After mixing for 5 minutes, the samples are cooled while mixing until the samples begin to gel. The gel is removed, hand-extruded to form droplets of about 5,000 microns in size, and allowed to harden.
Example 2
[0029] About 30 grams of pitch is melted at about 225° C. in a flask equipped with a mixer, such as a mixer sold under the trade designation L4RT by Silverson Machines, Inc. of East Longmeadow, Mass. The pitch can be ash-free and produced by collecting and fractionating a heavy product of a slurry hydrocracker. The pitch may have a density of 1.185 g/cc. The temperature is increased until the viscosity is reduced enough to allow thorough mixing at about 300° C. A release of water vapor may occur due to the relatively high temperature. While stirring, about 60 grams of the iron sulfate monohydrate is added. The iron sulfate monohydrate can have a bulk density of 1.9 g/cc and a crystal density of 3.0 g/cc with a voidage of about 36.7%. The pitch can be in a volumetric amount equivalent to about 10% of the void volume of the iron sulfate monohydrate particles for the purpose of binding the mass and sealing the outside of the granules. After mixing for 5 minutes, the samples are cooled while mixing until the samples begin to gel. The gel is removed, hand-extruded to form droplets of about 5,000 microns in size, and allowed to harden.
[0030] Without further elaboration, it is believed that one skilled in the art can, using the preceding description, utilize the present invention to its fullest extent. The preceding preferred specific embodiments are, therefore, to be construed as merely illustrative, and not limitative of the remainder of the disclosure in any way whatsoever.
[0031] In the foregoing, all temperatures are set forth in degrees Celsius and, all parts and percentages are by weight, unless otherwise indicated.
[0032] From the foregoing description, one skilled in the art can easily ascertain the essential characteristics of this invention and, without departing from the spirit and scope thereof, can make various changes and modifications of the invention to adapt it to various usages and conditions. | One exemplary embodiment can be a process for making a catalyst including an effective amount of iron for catalyzing one or more reactions in a hydrocarbon conversion system. The process can include grinding and coating the particles. The ground particles can have an effective amount of iron, and substantially all the particles may have a maximum dimension no larger than about 130 microns. The coating can have an effective amount of one or more hydrocarbons to provide the catalyst with improved flowability. | 2 |
FIELD OF THE INVENTION
[0001] This invention relates to personal care hair care compositions for emulating tousled and tangled hair styles and methods of making and using the compositions.
BACKGROUND OF THE INVENTION
[0002] A day at the beach can create untame, tousled, and voluminous hair. While such hair may seem unfavorable to some, achieving the look can be fashionable and desired by many. Salt, sand, and wind aid in creating the tousled, fashionable look. Exposure to these elements, however, can be damaging to hair. Dry hair is problematic because it makes hair weak and frizzy and causes unsightly split ends. Furthermore, achieving the look of having spent a day at the beach may not be possible for those that do not have access to such conditions.
[0003] Accordingly, achieving the “beach ready” hair look without having to spend a day at the beach has been attempted by application of various hair care products to the hair. Many such products, however, contain harmful ingredients that exacerbate the dry hair problem and may cause long term damage to hair. For example, many products contain large amounts of drying agents and lack protecting agents. Many products may also contain large portions of synthetic chemicals that are harmful to the user and may cause long-term ill health effects. Furthermore, many compositions require complex manufacturing processes thus increasing the cost of production.
[0004] It is a goal of the present invention to provide a hair care composition that does not dry out the hair, but that provides the fashionable tangled, tousled look of one who spent the day at the beach. The composition is preferably comprised of a large proportion of organic, natural ingredients. An economical method of making the composition and a method of using the composition to achieve a day-at-the-beach look for hair is also contemplated.
SUMMARY OF THE INVENTION
[0005] The present invention relates to a composition for the hair for creating tangled, tousled hair styles, also called “beach-ready” hair, comprising a vehicle, one or more texturizers, a shine enhancer, a fragrance, a protecting agent, a preservative, and optionally a coloring agent. In a preferred embodiment, the composition comprises a vehicle such as water, a texturizer such as sea salt, a shine enhancer and fragrance such as coconut oil (which can also function as a conditioner and texturizer), a protecting agent such as panthenol, a preservative such as specially denatured alcohol or “SD alcohol,” and optionally a coloring agent such as natural orange food coloring. Additional fragrance may be added. Other ingredients performing the aforementioned functions are contemplated.
[0006] The present invention also relates to a method of making the composition comprising boiling water, adding sea salt and simmering until dissolved, adding coconut oil and boiling until dissolved, cooling, removing and discarding any solid material in the cooled mixture by skimming and/or straining, and adding panthenol, alcohol, and an optional coloring agent to the remaining mixture. Additional fragrance may also be added to the mixture.
[0007] A method of using the composition for achieving untamed hair styles is contemplated comprising shaking the composition, spraying or spritzing it onto the hair, and styling as desired. The hair may be wet or dry.
DETAILED DESCRIPTION
[0008] The detailed description set forth below is intended as a description of exemplary embodiments and is not intended to represent the only forms in which these embodiments may be formulated and/or utilized. The description sets forth the functions and the sequence of steps for preparing and using the exemplary embodiments. It is to be understood, however, that the same or equivalent functions and sequences of steps for preparation and use may be accomplished by different embodiments that are encompassed within the spirit and scope of the specification. For example, the sample methods of making the composition provided may be scaled up or down depending upon the amount of composition desired. Alternatively, ingredients having the same functions as those ingredients noted herein may be substituted for the listed ingredients.
[0009] A hair care composition is contemplated comprising a vehicle, one or more texturizers, a shine enhancer and fragrance, a protecting agent, a preservative, and optionally a coloring agent. Additional ingredients such as fragrance may also be added.
[0010] The vehicle may be water; the texturizer may be sea salt; the shine enhancer and fragrance may be coconut oil (which also conditions and texturizes hair); the protecting agent may be panthenol; the preservative may be SD alcohol; and the optional coloring agent may be natural orange food coloring.
[0011] In another embodiment, the vehicle may be selected from the group consisting of water, SD alcohol, and mixtures thereof.
[0012] The protecting agents may be selected from the group consisting of panthenol, dexpanthenol, vitamin-B complex factor, provitamin B-5, lanolin, and mixtures thereof.
[0013] The shine enhancers may be selected from the group consisting of coconut oil, shea butter, almond oil, olive oil, chamomile oil, palm oil, rosemary extract, silicone, derivatives of silicone, henna, aloe vera, fruit extracts, green tea extract, jojoba, lemon juice, vinegar, and mixtures thereof.
[0014] The preservatives may be selected from the group consisting of SD alcohol, one or more of the essential oils such as thyme, organum, sweet orange, lemongrass, Chinese cinnamon, rose, clove, eucalyptus, peppermint, or rose geranium, and mixtures thereof.
[0015] The fragrances may be selected from the group consisting of coconut oil, fragrance, coumarin, hydroxyisohexyl 3-cyclohexene, carboxaldehyde, alpha-isomethyl ionone, butylphenyl methylpropional, limonene, linalool, geraniol, citral; butylmethoxydibenzoylmethane, ethylhexyl methoxycinnamate, ethylhexyI salicylate, and mixtures thereof.
[0016] In one embodiment, the composition comprises 70 to 90% vehicle, 5 to 20% texturizer(s), 0.5 to 10% shine enhancer and fragrance, 0.1 to 5.0% protecting agent, 0.05 to 5.0% preservative, and optionally 0.025 to 2.5% coloring agent, or equivalent proportions therein.
[0017] In a preferred embodiment, the composition comprises 80 to 90% vehicle, 7.5 to 15% texturizer(s), 1 to 5% shine enhancer and fragrance, 0.5 to 2.5% protecting agent, 0.5 to 1.5% preservative, and optionally 0.25 to 1.0% coloring agent, or equivalent proportions therein.
[0018] In a further preferred embodiment, the composition comprises in approximate percentages 82.4% vehicle, 12.4% texturizer(s), 1.95% shine enhancer and fragrance, 1.85% protecting agent, 0.9% preservative, and optionally 0.50% coloring agent.
[0019] In yet another embodiment, the composition comprises 17 to 22 L vehicle, 1.2 to 5.0 L texturizer(s), 0.12 to 2.50 L shine enhancer and fragrance, 0.02 to 1.30 L protecting agent, 0.01 to 1.30 L preservative, and optionally 0.006 to 0.60 L coloring agent, or equivalent proportions therein. For example, the composition may comprise 17 to 22 L water, 1.2 to 5.0 L sea salt, 0.12 to 2.50 L coconut oil, 0.02 to 1.30 L panthenol, 0.01 to 1.30 L SD alcohol, and optionally 0.006 to 0.60 L coloring agent, or equivalent proportions therein.
[0020] In another embodiment, the composition comprises 19 to 22 L vehicle, 1.8 to 3.7 L texturizer(s), 0.24 to 1.30 L shine enhancer and fragrance, 0.1 to 0.6 L protecting agent, 0.1 to 0.4 L preservative, and optionally 0.06 to 0.25 L coloring agent, or equivalent proportions therein.
[0021] In a further preferred embodiment, the composition comprises in approximate volumes, 20 L vehicle, 3 L texturizer(s), 0.473 L shine enhancer and fragrance, 0.459 protecting agent, 0.230 L preservative, and optionally 0.115 L coloring agent, or equivalent proportions therein.
[0022] In all of the aforementioned embodiments, additional fragrance may be added.
[0023] A method of making the composition is further contemplated comprising boiling water, adding sea salt until dissolved, adding coconut oil and bringing the composition to a boil, cooling the composition by removing from heat and/or refrigerating, removing and discarding solid material in the mixture by skimming and/or straining, and adding panthenol, alcohol, and an optional coloring is agent to the remaining mixture. The method may further comprise adding additional fragrance to the remaining mixture. The mixture may be poured into one or more small spray bottles or other containers either before or after adding panthenol, alcohol, and an optional coloring agent.
EXAMPLE 1
[0024] The hair care composition is made by bringing 20 liters of water to a boil. Three liters (or 12.68 cups) of sea salt is slowly added to the water, stirring constantly for 7-10 minutes. The temperature is then reduced so that the composition simmers. The composition simmers for approximately 10-15 minutes, stirring occasionally until all of the sea salt is dissolved. Once the sea salt is dissolved, two cups (or 0.473 liters) of organic coconut oil are added and the composition is brought to a boil. The composition is boiled for approximately 10 minutes or until the coconut oil is dissolved. Next, the heat is turned off, and the composition is cooled for about an hour. The composition is then placed in the refrigerator and cooled for at least 5 hours, or overnight. After cooling in the refrigerator, the solid, hardened layer that forms on the top of the composition is removed. Next, the contents are poured through a straining medium such as cheese cloth into a large, preferably a 22 quart, container. The straining medium is intended to filter out any remaining hardened pieces in the mixture. Alternatively, the hardened pieces may be skimmed from the mixture. Then, small bottles, preferably 2 ounce bottles, are substantially filled with the composition and ¼ teaspoon of panthenol (approximately 0.04 fluid ounces), 2 drops of SD alcohol (approximately 0.02 fluid ounces), and optionally 1 drop of 100% natural orange food coloring is added. The composition is sealed in the bottle and can be shaken prior to using.
EXAMPLE 2
[0025] The hair care composition is made by bringing 20 liters of water to a boil. Three liters (or 12.68 cups) of sea salt is slowly added to the water, stirring constantly for 7-10 minutes. The temperature is then reduced so that the composition simmers. The composition simmers for approximately 10-15 minutes, stirring occasionally until all of the sea salt is dissolved. Once the sea salt is dissolved, two cups (or 0.473; liters) of organic coconut oil are added and the composition is brought to a boil. The composition is boiled for approximately 10 minutes or until the coconut oil is dissolved. Next the heat is turned off, and the composition is cooled for about an hour. The composition is then placed in the refrigerator and cooled for at least 5 hours, or overnight. After cooling in the refrigerator, the solid, hardened layer that forms on the top of the composition is removed. Next, the contents are poured through a straining medium such as cheese cloth into a large, preferably a 22 quart, container. The straining medium is intended to filter out any remaining hardened pieces in the mixture. Alternatively, the hardened pieces may be skimmed from the mixture. Then, the following three ingredients are added to the mixture: 0.459 liters of panthenol, 0.230 liters of SD alcohol, and optionally 0.115 liters of 100% natural orange food coloring, and the resultant contents are mixed. Next, the composition is poured into bottles, preferably 2 ounce bottles. The composition is sealed in the bottle and can be shaken prior to using.
[0026] A method of using the composition to achieve an untamed, tousled hair style is also contemplated comprising shaking the composition and then spraying or spritzing the composition on dry or wet hair particularly the roots (and ends if blow drying is used for styling), and optionally styling the hair as desired. Styling the hair as desired may include styling using the hands, blow drying, using a curling iron or other heating device, or pinning the hair up in a hair ornament, pony tail elastic, clip, pin, or the like.
[0027] In particular a method of using the composition comprises spraying or spritzing on roots before blow drying to add volume; spraying or spritzing on ends after blow drying for individualized texture that gives a “flick” to the ends of the hair; spraying or spritzing on the roots before drying and before styling in an up-do to give expansion and texture to the hair; or spraying or spritzing on towel-dried hair and sculpting and letting air dry for a piecey texture and/or for creating air dried curls. The method may further comprise spritzing or spraying on hair throughout the day or a day after application to reactivate and volumize any style. | The present invention relates to personal care compositions, and in particular, a hair care composition for obtaining tangled and tousled hair styles. The compositions are preferably made of a large proportion of natural products and a minimal amount of drying agents and preservatives. In particular, the invention relates to a hair care composition comprising water, sea salt, coconut oil, panthenol, and SD alcohol. The invention further relates to methods of using the composition for obtaining fashionable tangled hair styles and methods of making the composition that are economical and easy to manufacture. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 09/928,571 filed Aug. 13, 2001, which is hereby incorporated by reference in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to a heat transfer medium having a high heat transfer rate, a heat transfer surface, and a heat transfer element utilizing the heat transfer medium.
BACKGROUND OF THE INVENTION
[0003] Efficiently transporting heat from one location to another always has been a problem. Some applications, such as keeping a semiconductor chip cool, require rapid transfer and removal of heat, while other applications, such as dispersing heat from a furnace, require rapid transfer and retention of heat. Whether removing or retaining heat, the heat transfer abilities of the material utilized define the efficiency of the heat transfer.
[0004] For example, it is well known to utilize a heat pipe for heat transfer. The heat pipe operates on the principle of transferring heat through mass transfer of a fluid carrier contained therein and phase change of the carrier from the liquid state to the vapor state within a closed circuit pipe. Heat is absorbed at one end of the pipe by vaporization of the carrier and released at the other end by condensation of the carrier vapor. Although the heat pipe improves thermal transfer efficiency as compared to solid metal rods, the heat pipe requires the circulatory flow of the liquid/vapor material and is limited by the material's vaporization and condensation temperatures. Consequently, the heat pipe's axial heat transfer rate is further limited by the magnitude of the material's latent heat of liquid vaporization and the rate of transformation between liquid and vapor states. Further, the heat pipe is convectional in nature and suffers from thermal losses, thereby reducing the thermal efficiency. It is generally accepted that when two substances having different temperatures are brought together, the temperature of the warmer substance decreases and the temperature of the cooler substance increases. As the heat travels along a heat-conducting conduit from a warm end to a cool end, available heat is lost due to the heat conducting capacity of the conduit material, the process of warming the cooler portions of the conduit and thermal losses to the atmosphere.
[0005] I disclose a heat transfer composition and the method for its preparation in U.S. Pat. No. 6,132,823, issued Oct. 17, 2000.
[0006] In that patent, the heat transfer medium was made up of three layers deposited on a substrate. The first two layers were prepared from solutions exposed to the inner wall of the conduit. The third layer was a powder comprising various combinations. The first layer was placed onto an inner conduit surface, the second layer was then placed on top of the first layer to form a film over than inner conduit surface. The third layer was a powder preferably evenly distributed over the inner conduit surface.
[0007] The first layer was nominated an anti-corrosion layer to prevent etching of inner conduit surface. The second layer was said to prevent the production of elemental hydrogen and oxygen, thus restraining oxidation between oxygen atoms and the conduit material. The third layer, referred to as the “black powder” layer, was said to be activated once exposed to a minimum activation temperature of 38° C. Consequently, it was said elimination of any of the three layers from the prior heat transfer medium might have an adverse effect on heat transfer efficiency.
[0008] In addition, the method for preparing the prior medium was complicated and cumbersome. For instance, formation of the first layer might involve nine chemical compounds prepared in seven steps. Formation of the second layer might involve fourteen compounds prepared in thirteen steps. Formation of the third layer might involve twelve compounds prepared in twelve steps. In addition, if the components of each layer were combined in an order not consistent with the listed sequence and conforming to the exceptions noted in my patent, the solutions made for such preparation were potentially unstable.
[0009] Generally, the heat transfer medium of the present invention eliminates or improves upon many of the noted shortcomings and disadvantages. The heat transfer medium of the present invention preferably is made up of a layer, most preferably a single layer, deposited on a substrate, prepared from a group of twelve inorganic compounds selected from the list below and formed in a single layer. The improved medium not only reduces the number and types of compounds used in the medium, but also effectively reduces the number of steps required for the preparation of the medium without compromising heat transfer efficiency.
SUMMARY OF THE INVENTION
[0010] The present invention provides a high heat transfer rate heat transfer medium that is useful in even wider fields, is simple in structure, easy to make, environmentally sound, and rapidly conducts heat and preserves heat in a highly efficient manner.
[0011] The present invention provides a heat transfer medium, typically inorganic in nature, which is a composition. The composition comprises or, in the alternative, consists essentially of the following compounds mixed together in the ratios or amounts shown below. The amounts may be scaled up or down as needed to produce a selected amount. Although the compounds are preferably mixed in the order shown, they need not be mixed in that order.
Cobaltic Oxide (Co 2 O 3 ), 0.5%-1.0%, preferably 0.7-0.8%, most preferably 0.723%; Boron Oxide (B 2 O 3 ), 1.0%-2.0%, preferably 1.4-1.6%, most preferably 1.4472%; Calcium Dichromate (CaCr 2 O 7 ), 1.0%-2.0%, preferably 1.4-1.6%, most preferably 1.4472%; Magnesium Dichromate (MgCr 2 O 7 .6H 2 O), 10.0%-20.0%, preferably 14.0-16.0%, most preferably 14.472%; Potassium Dichromate (K 2 Cr 2 O 7 ), 40.0%-80.0%, preferably 56.0-64.0%, most preferably 57.888%; Sodium Dichromate (Na 2 Cr 2 O 7 ), 10.0%-20.0%, preferably 14.0-16.0%, most preferably 14.472%; Beryllium Oxide (BeO), 0.05%-0.10%, preferably 0.07-0.08%, most preferably 0.0723%; Titanium Diboride (TiB 2 ), 0.5%-1.0%, preferably 0.7-0.8%, most preferably 0.723%; Potassium Peroxide (K 2 O 2 ), 0.05%-0.10%, preferably 0.07-0.08%, most preferably 0.0723%;
[0021] A selected metal or ammonium Dichromate (MCr 2 O 7 ), 5.0%-10.0%, preferably 7.0-8.0%, most preferably 7.23%, where “M” is selected from the group consisting of potassium, sodium, silver, and ammonium.
Strontium Chromate (SrCrO 4 ), 0.5%-1.0%, preferably 0.7-0.8%, most preferably 0.723%; and, Silver Dichromate (Ag 2 Cr 2 O 7 ), 0.5%-1.0%, preferably 0.7-0.8%, most preferably 0.723%.
[0024] The percentages expressed just above are weight percentages of the final composition once the composition has been dried to remove the added water.
[0025] The present invention also provides a heat transfer surface comprising a surface substrate covered at least in part by the high heat transfer rate inorganic heat transfer medium of the present invention.
[0026] The present invention also provides a heat transfer element comprising the high heat transfer rate inorganic heat transfer medium situated on a substrate.
[0027] The objects and advantages of the invention will become apparent from the following detailed description of the preferred embodiments thereof in connection with the accompanying drawings, in which like numerals designate like elements.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] FIG. 1A shows a perspective view of heat transfer pipe element according to the present invention.
[0029] FIG. 1B shows a cross-sectional view of the element in FIG. 1A .
[0030] FIG. 1H shows the result of one such experiment in which the heater input power was stepped progressively from 9 to 20 to 178 watts.
[0031] FIG. 1I is a plot of the steady-state temperature difference (sensor T° minus ambient T°) for each of the sensors and their mean value versus input power.
[0032] FIG. 1J shows transient temperature rise due to 20-178 watts heater power, step.
[0033] FIG. 1K shows these same resistance data plotted versus the mean temperature recorded by the thermocouple temperature sensors in the respective halves of the tube.
[0034] FIG. 1L shows the expected heat transfer coefficients for carbon steel pipe versus surface temperatures.
[0035] FIG. 1M shows the predicted and observed transition temperature response to a heater input power step from 20 to 178 watts.
[0036] FIG. 1N shows the results of finite transmission line model calculations for the prediction of the temperature distribution along the tested heat tube.
[0037] FIG. 1O shows a diagram of the demonstration heat transfer tube of the first heat exchanger attached (Diff1), designed to test the principle of measuring thermal conductivity in a differential temperature system.
[0038] FIG. 1P shows another kind of heat transfer tube (Diff2) with a hollow acrylic cylinder attached to the end of the heat transfer tube with water flowing through the cylinder.
[0039] FIG. 1Q shows these two calorimeter designs, Diff1 and Diff2, operated in the range of input powers from 100 to 1500 W and flow rates from 1 to 85 g/sec. The corresponding heat flux densities (phi) range 0.11×10 6 to 1.7×10 6 W/m 2 and the heat recovery ranges from 300 to 1500 watts.
[0040] FIG. 1R shows the heat recovery profile along the demonstration heat transfer tube measured using Diff1 and Diff2.
[0041] FIG. 1S is a plot of the difference of these two temperatures versus heat flux density.
[0042] FIG. 1T shows the measurements of effective thermal conductance versus heat flux density for all input powers up to 2000W, 2.2×10 6 W/m 2 .
DESCRIPTION OF THE INVENTION
Composition
[0043] The present invention provides a heat transfer medium, which is regarded as a composition, having high heat transfer rate. The composition comprises or, in the alternative, consists essentially of the following compounds mixed together in the ratios or amounts shown below. The amounts may be scaled up or down as needed to produce a selected amount. Although the compounds are preferably mixed in the order shown, they need not be mixed in that order.
Cobaltic Oxide (Co 2 O 3 ), 0.5%-1.0%, preferably 0.7-0.8%, most preferably 0.723%; Boron Oxide (B 2 O 3 ), 1.0%-2.0%, preferably 1.4-1.6%, most preferably 1.4472%; Calcium Dichromate (CaCr 2 O 7 ), 1.0%-2.0%, preferably 1.4-1.6%, most preferably 1.4472%; Magnesium Dichromate (MgCr 2 O 7 .6H 2 O), 10.0%-20.0%, preferably 14.0-16.0%, most preferably 14.472%; Potassium Dichromate (K 2 Cr 2 O 7 ), 40.0%-80.0%, preferably 56.0-64.0%, most preferably 57.888%; Sodium Dichromate (Na 2 Cr 2 O 7 ), 10.0%-20.0%, preferably 14.0-16.0%, most preferably 14.472%; Beryllium Oxide (BeO), 0.05%-0.10%, preferably 0.07-0.08%, most preferably 0.0723%; Titanium Diboride (TiB 2 ), 0.5%-1.0%, preferably 0.7-0.8%, most preferably 0.723%; Potassium Peroxide (K 2 O 2 ), 0.05%-0.10%, preferably 0.07-0.08%, most preferably 0.0723%;
[0053] A selected metal or ammonium Dichromate (MCr 2 O 7 ), 5.0%-10.0%, preferably 7.0-8.0%, most preferably 7.23%, where “M” is selected from the group consisting of potassium, sodium, silver, and ammonium.
Strontium Chromate (SrCrO 4 ), 0.5%-1.0%, preferably 0.7-0.8%, most preferably 0.723%; and, Silver Dichromate (Ag 2 Cr 2 O 7 ), 0.5%-1.0%, preferably 0.7-0.8%, most preferably 0.723%.
[0056] The percentages expressed just above are weight percentages of the final composition once the composition has been dried to remove the added water.
[0057] A most highly preferred composition is made in the following way. The following inorganic compounds are added in the amounts shown below (+/−0.10% of each compound) and in the manner discussed below:
Cobaltic Oxide (Co 2 O 3 ), 0.01 g; Boron Oxide (B 2 O 3 ), 0.02 g; Calcium Dichromate (CaCr 2 O 7 ), 0.02 g; Magnesium Dichromate (MgCr 2 O 7 .6H 2 O), 0.2 g; Potassium Dichromate (K 2 Cr 2 O 7 ), 0.8 g; Sodium Dichromate (Na 2 Cr 2 O 7 ), 0.2 g; Beryllium Oxide (BeO), 0.001 g; Titanium Diboride (TiB 2 ), 0.01 g; Potassium Peroxide (K 2 O 2 ), 0.001 g; “M” Dichromate (MCr 2 O 7 ), 0.1 g; where “M” is selected from the group consisting of potassium, sodium, silver, and ammonium, Strontium Chromate (SrCrO 4 ), 0.01 g; and Silver Dichromate (Ag 2 Cr 2 O 7 ), 0.01 g.
[0070] The compounds are added sequentially in the order listed just above to a container containing 100 ml of generally pure, preferably twice-distilled, water until dissolved. The mixture is mixed at ambient temperature, e.g., about 18-20° C. an then preferably heated to a temperature in the range of 55-65° C., preferably about 60° C. and then stirred and mixed at such temperature for, e.g., about 20 minutes, until complete dissolution is attained. The composition is and is then ready for application.
[0071] The heat transfer medium of the present invention may be applied to any suitable substrate, e.g., placed upon a metal conduit or even glass conduit, so long as the chosen surface is substantially free of metallic oxides, grease or oils. To optimize the quality of the resulting heat transfer composition, it is preferable to apply the composition in a very low humidity environment, e.g., 35-37% relative humidity, in any event less than about 40% relative humidity. It is also desirable to apply the composition to a closed volume that is isolated from water (vaporous or liquid) once applied.
[0072] To achieve desirable thermal conductivity in a heat conducting conduit or chamber containing the composition, the quantity of the heat transfer medium of the present invention added into the chamber is dependent on the volume of that cavity. Preferably, the (volume of composition/volume of cavity) ratio is desirably is maintained in the following ratio ranges: 0.001 to 0.025, more preferably 0.01 to 0.025, most preferably in the following ratios: 0.025, 0.02, 0.0125, and 0.01. There is no need to perform any pre-coating step for the conduit. Once the conduit is packed or filled with desirable amount of the medium, the conduit is heated up to 120° C. to permit evaporation of the twice-distilled water. The conduit or chamber is then sealed and is ready for use as a heat conducting device.
[0073] The amount of heat transfer medium of the present invention used to prepare the conduit may be varied according to the intended use of the finished products. The preparation of the improved medium and the manufacture of the thermal conductivity surfaces or conduits using the heat transfer medium of the present invention can be achieved and completed in one single step.
[0074] The improved medium is operable at a temperature range of 70-1800° C. without losing its characteristics. The surface may be constructed in any shape pursuant to the shapes of the intended products without being restricted by any construction angles. For instances, the conduit may be made in a straight, curved, zigzag, grid, spiral, or a snake-like shape.
[0075] It has been observed that thermal conductivities and heat transfer rates for the medium of the present invention are in excess of 32,000 times that of pure, metallic silver.
[0076] It should be noted that if the components of the improved medium are combined in an order not consistent with the listed sequence, the medium can become unstable and may result in a catastrophic reaction. Further, should metals be used as substrates for the medium of the present invention, it is recommended that the metal be clean, dry, and free of any oxides or scales. This can be accomplished by conventional treating by, for example, sand blasting, weak acid washing, or weak base washing. Any materials used to clean and treat the conduit should be completely removed and the inner conduit surface also should be dry prior to adding the medium to conduit.
EXAMPLE 1
[0077] A high heat transfer heat medium was prepared by the following process, and the compounds were added in the manner as discussed below:
Cobaltic Oxide (Co 2 O 3 ), 0.01 g; Boron Oxide (B 2 O 3 ), 0.02 g; Calcium Dichromate (CaCr 2 O 7 ), 0.02 g; Magnesium Dichromate (MgCr 2 O 7 .6H 2 O), 0.2 g; Potassium Dichromate (K 2 Cr 2 O 7 ), 0.8 g; Sodium Dichromate (Na 2 Cr 2 O 7 ), 0.2 g; Beryllium Oxide (BeO), 0.001 g; Titanium Diboride (TiB 2 ), 0.01 g; Potassium Peroxide (K 2 O 2 ), 0.001 g; “M” Dichromate (MCr 2 O 7 ), 0.1 g; where “M” is selected from the group consisting of potassium, sodium, silver, and ammonium, Strontium Chromate (SrCrO 4 ), 0.01 g; and Silver Dichromate (Ag 2 Cr 2 O 7 ), 0.01 g.
[0090] The compounds were added sequentially in the order listed just above to a container containing 100 ml of twice-distilled water until dissolved. The mixture was mixed at ambient temperature of 20° C. and then heated to the temperature of 60° C. and then stirred and mixed at such temperature for 20 minutes, until complete dissolution was attained. The composition was then ready for application.
EXAMPLE 2
[0091] The composition obtained from Example 1 was used as the heat transfer medium of the present invention. To optimize the quality of the resulting heat transfer composition, it is preferable to apply the composition in any event less than about 40% relative humidity. Under the relative humidity of 36%, the heat transfer medium of the present invention was applied to a metal conduit substrate. The metal substrate is selected from carbon steel, stainless steel, aluminum, copper, titanium, and nickel and alloys thereof, or non-metal conduit, either glass or ceramic, and then formed into the required heat transfer element. The selected surface of the substrate is substantially free of metallic oxides, grease or oils.
[0092] To achieve desirable thermal conductivity in a heat conducting conduit or cavity containing the composition, the quantity of the heat transfer medium of the present invention applied was dependent on the volume of that cavity or conduit. The medium of the present invention was applied over the selected surface, an inner wall of the cavity or conduit, in (volume of composition/volume of cavity) ratios of 0.025, 0.02, 0.0125, and 0.01. There was no need to perform any pre-coating step for the cavity or conduit. Once the cavity or conduit was packed or filled with desirable amount of the medium, it was heated up to 120° C. to permit evaporation of the twice-distilled water. After the application of the heat transfer composition on the substrate, the substrate with the heat transfer medium of the present invention was then sealed in the conduit or cavity isolated from water (vaporous or liquid) and was ready for use as a heat conducting device.
[0093] The amount of the heat transfer medium of the present invention used to prepare the conduit may also be varied according to the intended use of the finished products. The preparation of the improved medium and the manufacture of a high heat transfer surfaces (of cavity or conduit) using the heat transfer medium of the present invention was achieved and completed in one single step.
[0094] The improved medium was operated at a temperature range of 70-1800° C. without losing its characteristics. The surface was constructed in various shapes pursuant to the shapes of the intended products without being restricted by any construction angles. For instances, the conduit was made in a straight, curved, zigzag, grid, spiral, or a snake-like shape in required dimension and appearance to comply with various fields of applications.
[0095] A standard heat pipeline is a technique of rapidly transferring thermal energy from a hot end to a cold end of the pipeline by the absorption and emission of extensive amount of latent heat during the liquid vaporization and vapor condensation respectively. The heat transfer rate in axial direction depends on the vaporization heat of a liquid and the transformation rate between liquid and vapor, in addition to the limitation of substrate materials, temperature and pressure.
[0096] A pipe element of the present invention axially transferred heat in a rate much faster than that of any other metal bars or standard heat pipelines. The pressure intensity inside the pipe element was much lower than that of any other heat pipes. The upper limit of the allowed temperature equaled to the highest temperature of application for the materials of the pipe element. According to the present invention, the pipe element may be designed and manufactured to meet the various requirements in size and shape.
[0097] FIGS. 1A and 1B show perspective and, cross-sectional views, respectively, of a heat-transfer pipe according to the present invention. As shown in these two diagrams, a heat-transfer pipe element 102 comprises a heat transfer medium 110 applied to a surface of inner wall of the heat-transfer pipe element, a cavity 105 , a conduit 108 , a bore 106 , and a plug 104 for sealing the bore 106 .
[0098] The heat transfer pipe elements of the present invention were jointed together with each, referred to as a pipe-pipe element, for practical uses. The pipe-pipe element had features such as high efficient heat transfer rate, well-distributed temperature, high variety in assembly, and changeable density of heat flow etc. The heat exchanger made of the pipe-pipe elements was characterized by compact or small volume and low surface dissipation which increased the heat efficiency and thus save electrical energy. The various pipe-pipe elements were independent so that damage to the end of any element would not result in mixing of two kinds of exchange fluids. Any damage to an individual pipe-pipe element would not affect the normal function of the other elements. Damage or malfunction in small parts of the pipe-pipe elements would not affect the normal operation of the entire equipment.
Procedure for Measuring Heat Transfer Efficiency
[0099] A pair of the pipe elements in Example 1 were made to demonstrate the thermal conductivity and effective thermal conductance of the heat transfer medium of the present invention and to exemplify the use of the material in a heat transfer process.
[0100] The demonstration tubes had dimensions of 2.5-cm diameter (dia.)×1.2-m length, with an open cylindrical attachment of 7.5-cm dia.×10-cm length welded to one end to accommodate a close-fitting and slightly tapered heater insert (5-cm dia.×9-cm length). The interiors of the demonstration tubes, after cleaning, were coated with a thin coating of the heat transfer medium of the present invention made according to the procedure recited above.
[0101] The demonstration heat transfer tubes were instrumented by attaching up to nine calibrated thermocouples at well-defined positions along the outer circumference of the tube. Temperatures at these points were monitored and recorded as they responded to varying levels of electrical heat input to the heater located at the base of the tube. In some instances, redundant temperature sensors and monitoring instruments were used, particularly at the two ends of the tube, to ensure that no significant mis-measurement of temperature occurred.
[0102] These experiments were performed in a safety-sealed vented closure of approximate dimensions 1.2×1.6×1.0 m. To minimize temperature stratification within the test chamber, the experiment was operated with a demonstration heat transfer tube situated at an angle of 10° from the horizontal. Input powers and temperatures were monitored in this configuration to quantify the heat transfer rate within the demonstration heat transfer tube.
[0103] The various temperatures were measured using seven Type J thermocouples placed equidistantly along the 1.2-meter section of the 2.5-cm diameter tube. Another thermocouple was placed on the larger diameter tube housing the heater. These thermocouples were held in place using steel hose clamps. The remaining thermocouple measured room temperature.
[0104] The thermocouples were connected to a Keithley #7057A thermocouple scanner card inside a Keithley 706 scanner. The junction block on the 7057A has a thermistor temperature sensor and was used to compensate for the cold-temperature junction. Standard fourth-order polynomials were used to perform the junction compensation and temperature calculations.
[0105] Power was supplied to the tube heater from a Hewlett Packard (HP) 66000A power supply mainframe with eight HP 66105A 1.25A/120V power modules. Two sets of four power supplies were wired in parallel, with the net output of the two sets wired in series to yield a 5 A/240 V power supply. This power supply system yields a very stable heater power over the length of the experiment. The actual current was measured as a voltage across a Kepco 0.1-Q/200 watt (W) standard current resistor in series with the heater. The heater voltage was measured by voltage sense wires attached to the heater terminals.
[0106] These two voltages were measured by a Keithley 7055 general purpose scanner card in the same model 706 scanner mentioned above. The output of the scanner boards were sent to a Keithley 195A 5 1 digital multi-meter (DMM) operating in direct current voltage mode. A Macintosh IIsi computer, using an IOTech model SCS1488 IEEE-488 interface, controlled the scanner and DMM. The results were saved to the computer's hard disk and accessed for analysis. The data acquisition software was written in Future Basic. The data, after analysis, was displayed using Microsoft Excel spreadsheet software.
Determination of Thermal Conductivity
[0107] After the tube was placed near horizontal, similar measurements were continued using up to 300 W input power, yielding a temperatures up to 150° C. above room temperature. Seven experiments were performed in the horizontal mode, including the final experiment where the power was stepped back and forth between 170 and 300 W over a 10-day period.
[0108] Several experiments were performed to measure the distribution of temperatures on the surface of the heat tube and the transient response to a step-function increase in heater input power. Nine identical and calibrated thermocouples were used in these tests: 1.) one thermocouple monitoring ambient temperature (T air ), 2.) one thermocouple affixed to the cylindrical heater mount (T heat ), and 3.) seven thermocouples placed equidistantly along the axis of the tube (at the “12:00” position, designated T 2 to T 8 , with the smaller numbers closer to the heater).
[0109] FIG. 1H shows the result of one such experiment in which the heater input power was stepped progressively from 9 to 20 to 178 W. FIG. 1I plots the steady-state temperature difference (sensor T° minus ambient T°) for each of the sensors and their mean value versus input power. The solid line in FIG. 1I is the quadratic best fit to the mean temperature values, with the coefficients specified. This line displays the expected form for heat dissipation from a pipe at uniform temperature, namely, a small negative second-order departure from linear dependence. What is unexpected is the degree to which the temperatures were, and remained, uniform along the extended length of an essentially empty pipe, heated at just one end.
[0110] Examining more closely the large power step from 20 to 178 W, it may be observed that the rise in temperature occured, on the time scale of measurement, quite quickly at all points along the heated demonstration tube. Temperature sensors T 2 -T 8 and their average value are plotted as lines in FIG. 1J , as a function of time for the two hours immediately following the power step. For the first 45 minutes, data were collected every minute, following that, every 5 minutes. On the scales presented, no significant positional variation of temperature can be resolved; the demonstration tube behaved as if it were heated uniformly along its axis.
[0111] Three other data sets were plotted in FIG. 1J , but they coincided so closely as to be difficult to resolve; the asterisks are the temperatures predicted for the dissipation of the heat corresponding to a 20 to 178 W power step to a uniformly heated horizontal steel pipe of dimensions identical to that of the heat tube. The details of this model are discussed below.
[0112] The points plotted as open diamonds and circles in FIG. 1J are ratios of resistances measured in the metal phase along the axis of the pipe. The resistance of a metal changes predictably with temperature according to the formula,
R=R °(1 +αT ) (1)
So that
T= ( R/R°− 1)/α
where R° is the resistance measured at T=0° C.
[0114] The data points labeled R bot refer to a resistance measurement made in the half of the tube closest to the heater, while those labeled R top refer to the resistance in the upper half of the tube. FIG. 1K shows these same resistance data plotted versus the mean temperature recorded by the thermocouple temperature sensors in the respective halves of the tube. From the regression lines plotted in FIG. 1K , it is clear that equation [1] above is well obeyed and that the temperature coefficient of resistance of the steel used in the tube is 0.428±0.001% K −1 .
[0115] The significance of the resistance data in FIGS. 1J and 1K is that 1.) there is no obvious error in the thermocouple temperature measurements, 2.) the measurements made on the surface of the tube conform closely with the volumetric temperatures recorded by the resistance ratio, and 3.) at all times, the average temperatures of the tube far from the heater were indistinguishable from those measured close to the heater despite the point location of the heat source.
Effective Heat Transfer Rates
[0116] The transfer of heat from carbon steel pipes is a very well known and very well understood problem of considerable engineering significance.
[0117] The rate of heat transfer by natural convection and radiation from the surface of a horizontal, bare, standard carbon steel pipe is well described in reference texts by a set of empirical equations and determined constants. FIG. 1L plots the expected heat transfer coefficient of a one inch-diameter carbon steel pipe, versus surface temperature. A parabolic regression line was fitted through the data points calculated from tabulated constants. This regression function was used to match the observed steady-state and transient response of the demonstration heat tube surface temperatures in response to stepped increases in the heater power.
[0118] A simple numerical model of 210×10 elements was constructed to solve the differential equation describing the rates of heat input, storage, and loss to the heat transfer tube. This model was constructed using two assumptions: 1.) the function presented in FIG. 1L accurately describes the heat loss from the tube surface, and 2.) the heat input at one end is communicated quite quickly (effectively instantaneously for the purposes of this calculation) to all parts of the metal tube.
[0119] This second assumption is consistent with observations and is, therefore, necessary to rationalize the data.
[0120] FIG. 1M shows the results of one such numerical calculation and the heat transfer coefficients shown in FIG. 1L , with the heat capacity of steel assigned the value of 0.54 J g −1 . The (measured) input power is partitioned into an amount stored by the heat capacity of the tube (P store ) and an amount dissipated by natural convection and radiation to the ambient (P lost ). Taking into account the slight increase in the (measured) ambient temperature, the model predicted and the measured average temperature responses coincide closely. The predicted steady-state heat dissipation is slightly (2%) larger than the measured input power. This discrepancy is easily accommodated by model errors, the effects of temperature sensors on heat dissipation, and the 10° departure of the tube from horizontal configuration.
[0121] For the case shown in FIG. 1M , as well as several other cases tested, it is clear that the model assumptions are well obeyed. That is, the demonstration heat conductor tube acted thermally as a standard carbon steel pipe uniformly heated throughout.
Heat Transfer Coefficient
[0122] Above, for the purposes of the model, the assumption was made, consistent with observation, that the tube was uniformly heated. Since the demonstration heat transfer tube was actually heated only at one end, this assumption was evidently erroneous.
[0123] With the tube heated at one end, the pattern of heat flow can be modeled as a one-dimensional transmission line. Using this concept, heat is conducted, in each successive element from the heater along the tube length: 1.) axially by whatever medium fills the inner tube volume, 2.) radially through the steel wall to the outer surface (where temperature is monitored), 3.) radially to the surrounding ambient air, the temperature of which is considered to be fixed.
[0124] Taking these terms in reverse order, the rate of heat transfer from the tube surface to the surrounding air is the function described by the blue line in FIG. 1L . Also shown in FIG. 1L are known data for the thermal conduction of iron (Fe), together with a parabolic regression fit and extrapolation.
[0125] FIG. 1N shows the results of comparative model calculations designed to predict the temperature distribution along the heat tube, performed as if the tube was filled with elemental silver (Ag). Silver is taken as a reference material because it is the best-known conductor of heat of all the elements in their normal allotropic form (diamond is superior in this regard). At 4.3 W cm −1 K −1 , silver conducts heat about 5.5 times better than Fe (which is taken to represent the carbon steel of the pipe).
[0126] The upper line in FIG. 1N shows the expected distribution in temperature along the tube, calculated for heater input power of 178 W, presuming that the pipe is filled with a medium having the same thermal conductivity as silver (4.3 W cm −1 K −1 ). The temperatures measured under this condition at the eight sensors placed along the axis of the tube are shown by the solid data points.
[0127] FIG. 1N shows clearly that the measured temperature profile is much flatter than that predicted if the inner volume conducted heat at the rate and with the mechanism of solid silver metal. Calculations were performed assigning successively higher conductivities to the inner volume: 2×, 5×, 10×, 100×, and 1,000×that of silver. Only the last calculated value is consistent with the measured values. Said another way: the tube conducted heat as if it were filled with a material having a thermal conductivity much greater than, e.g., at least 1000 times, that of silver. Although the results are shown for only one test (at 178 W of heater input power), this conclusion is consistent with the results of numerous tests of the heat tubes, in more than one configuration, and for a range of input powers.
[0128] There are no other apparent explanations of the observed axial temperature profiles. For instance, although heat pipes (in which heat transfer occurs by evaporation, vapor transport, and condensation of a working fluid) transfer heat at high rates, evidence against such a possibility may be made on the basis of the wide range of operative temperatures possible for the demonstration heat transfer tubes. Heat pipes operate at discrete temperature points or intervals.
Determination of Effective Thermal Conductance
[0129] A classical heat pipe's heat flux (Φ) is calculated as the input power (W) over the pipe's cross-sectional area. The maximum heat flux is determined by plotting the measured temperature difference (T) between the sink and source ends of the heat pipe versus Φ, under no-load conditions. The value of Φ, where the TΦ value deviates from that measured in the normal operating region, is the maximum heat flux density (Φ MAX ). The temperature at the source and sink of the demonstration heat transfer tube was measured as the input power (expressed as heat flux density) was increased. No maximum heat flux density (Φ MAX ) was calculated, because the T/Φ plot showed no positive deviation in T.
[0130] A classical heat pipe's effective thermal conductance (K eff ) is calculated by treating the pipe as a monolithic thermal conductor. Hence (K eff ) is defined as
( K eff )=[ P ( W )−1 /A] /( T 2 −T 1 )( K )
where P in the input power, I is the length of the tube, A is the tube's cross-sectional area, T 2 is the temperature at the sink end of the tube, and T 1 is the temperature at the source end. The source and sink temperatures were measured. Several temperatures in between the ends were also measured while the input power was varied under no-load conditions. All the experiments were performed without insulation wrapped around the pipe.
[0132] Another approach in measuring (K eff ) is to perform the same studies under different loads, allowing better control of operating temperature. The same experiments described above were then performed with three different heat exchangers attached to the sink end of the demonstration heat transfer tube. The source and sink temperatures were measured. Temperatures at locations intermediate the ends were also measured while varying the input power under varying load conditions. The load was supplied by circulating constant temperature water through the heat exchanger using a 6000-W recirculating chiller. K eff was calculated according to equation (1).
[0133] FIG. 1O shows a diagram of the demonstration heat transfer tube with the first heat exchanger attached. This configuration was referred to as Diff1 and was designed to test the principle of measuring thermal conductivity in a differential temperature system.
[0134] The first heat exchanger was a copper coil held to the demonstration heat transfer tube using Omegatherms 200 high thermal conductivity epoxy paste. However, the conductivity of this epoxy was only −0.003 times that of copper. Hence the epoxy presented a significant thermal resistance to heat flowing into the heat exchanger. To eliminate this thermal resistance, a second design, Diff2—using a second demonstration heat transfer tube, was made up of a hollow acrylic cylinder attached to the end of the demonstration heat transfer tube with water flowing through the cylinder. Diff2 is shown in FIG. 1P .
[0135] These two calorimeter designs, Diff1 and Diff2, were operated in the range of input powers from 100 to 1500 W and flow rates from 1 to 85 g/sec. These correspond to heat flux densities (phi) of 0.11×10 6 to 1.7×10 6 W/m 2 . The heat recovery from 300 to 1500 watts is shown in FIG. 1Q .
[0136] The efficiency using Diff1 was about 72% and using Diff2 was about 93%. This difference in efficiency was as expected considering the relatively poor thermal conductivity epoxy used in Diff1. FIG. 1R shows the heat recovery profile along the demonstration heat transfer tube measured using Diff1 and Diff2.
[0137] Because of the higher thermal recovery efficiency, input powers up to 3000 watts using Diff2 were used. In both cases the temperature was highest 27 cm from the heater. This was compared to the temperature 107 cm from the heater because temperatures farther from the heater were colder, due to the influence of the heat exchanger. The difference of these two temperatures was plotted versus heat flux density and is shown in FIG. 1S .
[0138] The useful operating range of the classical heat pipe will be where the plot remains linear or shows a negative deviation. Above the useful operating temperature, T will become disproportionately larger, because heat is transported less efficiently to the sink end of the tube. For all conditions measured, T of the demonstration heat transfer tube increased with heat flux density, showing that the maximum heat flux density was never achieved. The only exception was above 2000W when the 107-cm temperature was greater than the 27-cm temperature. For this reason, data above 2000W input power, 2.2×10 6 W/m 2 were not plotted.
[0139] FIG. 1T summarized the measurements of effective thermal conductance versus heat flux density for all input powers up to 2000W, 2.2×10 6 W/m 2 . These are presented as a ratio of (K eff ) to the thermal conductivity of silver (for comparison with what would be expected if the pipe were filled with solid silver, the highest thermally conducting metal). The maximum ratio found was greater than 30,000.
[0140] Although I have shown and described specific embodiments of the present invention, further modifications and improvements will occur to those skilled in the art. I desire it to be understood, therefore, that this invention is not limited to the particular forms shown and I intend the appended claims to cover all modifications that do not depart from the spirit and scope of the present invention. | A heat transfer medium is shown, having a very high heat transfer rate that is simple in structure, easy to make, environmentally sound, rapidly conducts heat, and preserves heat in a highly efficient manner. Also shown is a heat transfer surface and a heat transfer element utilizing the heat transfer medium. | 8 |
TECHNICAL FIELD
[0001] The present invention relates to a tie for binding materials to be tied such as reinforcing bars, a tie assembly, and a tie attachment device.
BACKGROUND OF INVENTION
[0002] Conventionally, reinforcing bars are arranged inside of concrete columns and walls in reinforced concrete buildings. For example, in a reinforced concrete column, a plurality of reinforcing bars are arranged along the direction of the column, and reinforcing bars are further arranged in horizontal direction intersecting with the reinforcing bars in a horizontal direction. Such reinforcing bars are installed prior to pouring concrete in a formwork and an intersectional portion of the reinforcing bar in the vertical direction (vertical reinforcement) and the reinforcing bar in the horizontal direction (horizontal reinforcement) are fixed by twisting a wire. Such procedure of twisting wires takes time and effort, thus connection and fixation tools for fixing intersectional reinforcing bars and devices for twisting wires have been proposed, as follows:
[0003] [Patent document 1] Japanese Published Unexamined Patent Application No. 2005-320816;
[0004] [Patent document 2] Japanese Published Unexamined Utility Model Application No. S60-87930;
[0005] [Patent document 3] Japanese Published Unexamined Utility Model Application No.S61-20625; and
[0006] [Non-patent document 1] Binding machine http)://www9.ocn.ne.ip/{tilde over ( )}tairiku/PicHomePage0/vw 7.html
BRIEF SUMMARY OF THE INVENTION
[0007] However, while the conventional connecting tools described above save the effort of twisting wire for binding, it is bulky for preparing large amounts because the ties are in complicated forms. For this reason, it is inconvenient to carry. Also, there is a problem of difficulty in the attachment work.
[0008] Further, the binding machine described in non-patent document 1 is a device having a motor driven by electricity and binds reinforcing bars by twisting wires around, however, the machine is not suitable for working for a long time due to its large weight, and there is a problem of a further increase of the weight when a battery is used because the power wire supplying electricity disturbs the work.
[0009] The present invention has been made in consideration of these issues, and it is therefore an objective of the present invention to: 1) provide a reinforcing bar tie which connects intersectional reinforcing bars; 2) provide a tie assembly that connects a plurality of ties for easy attachment; and 3) provide a tie attachment device for each attachment to the intersectional portion of the reinforcement bars.
[0010] The objectives are achieved by the present invention described as below.
[0011] (1) A tie for twisting around at an intersectional portion of a plurality of materials to be tied to bind these materials, wherein the tie consists of a wire rod made of elastic material formed in an arc, where the clearance between both ends is larger than the minimum width of the bound portion of material to be tied when both ends are opened within an elastic deformation range, and the maximum inner diameter in a restored state is smaller than the maximum width of the bound portion of materials to be tied.
[0012] (2) The tie according to (1) above, wherein the tie is for binding a pair of materials to be tied.
[0013] (3) The tie according to (2) above, wherein an intersectional portion of crossed material to be tied is a bound portion.
[0014] (4) The tie according to (2) above, wherein the bound portion is a portion of overlap of materials to be tied which are arranged in parallel.
[0015] (5) The tie according to any one of (1) to (4) above, wherein both ends of said arc wire rod have curved portions curving opposite to the direction of the curve of the arc.
[0016] (6) The tie according to any one of (1) to (5) above, wherein said wire rod has a rupture portion to be ruptured when a deformation value exceeds an elasticity limit.
[0017] (7) The tie according to (6) above, wherein said rupture portion is provided on the midsection of an axial direction of said wire rod.
[0018] (8) The tie according to (6) or (7) above, wherein said rupture portion is a portion smaller in area of cross-section of said wire rod than another portion.
[0019] (9) The tie according to (8) above, wherein said rupture portion is a groove or a cut formed in a direction perpendicular to the axial direction of said wire rod.
[0020] (10) The tie according to one of any (1) to (9) above, wherein a portion of both end portions of said wire rod is crossing in a restored state.
[0021] (11) The tie according to one of any (1) to (10) above, wherein said wire rod having one, or two or more loops formed in an arc as an overall shape and a portion is configured by curving outward.
[0022] (12) A tie assembly for connecting an inserting member inserted between both ends of a tie through a thin walled connecting portion, wherein the tie consists of a wire rod made of elastic material formed in an arc, the clearance between both ends is larger than the minimum width of the bound portion of material to be tied when both ends are opened within an elastic deformation range, and the maximum inner diameter in a restored state is smaller than the maximum width of the bound portion of material to be tied.
[0023] (13) A tie attachment device consisting of;
[0024] a guiding member positioned between both ends of a tie for guiding to a direction, wherein a tie consists of a wire rod made of elastic material formed in an arc, the clearance between both ends is larger than the minimum width of the bound portion of material to be tied when both ends are opened within an elastic deformation range, and the maximum inner diameter in a restored state is smaller than the maximum width of the bound portion of material to be tied;
[0025] a storing portion positioned between said guiding member for storing the material to be tied;
[0026] an extruding member positioned posterior to said guiding member for extruding a tie forward; and
[0027] an operation means for advancing said extruding member;
[0028] wherein said extruding member is capable of reciprocal motion between a standby position forming a reception space to house a tie between said guiding member, and an attachment position where both ends of a tie exceeding the frond end of the guiding member.
[0029] (14) The tie attachment device according to (13) above, wherein a groove for guiding both end portions of the tie is formed on an outer face of said guiding member.
[0030] (15) The tie attachment device according to (13) or (14) above, wherein the tie attachment device for feeding a tie to a reception space has a reception portion between said guiding member and said extruding member.
[0031] (16) The tie attachment device according to (15) above, wherein a tie assembly is housed in said reception portion, wherein the tie assembly connects an inserting member inserted between both ends of a tie through a thin walled connecting portion, and the tie consists of a wire rod made of elastic material formed in an arc, the clearance between both ends is larger than the minimum width of the bound portion of material to be tied when both ends are opened within an elastic deformation range, and the maximum inner diameter in a restored state is smaller than the maximum width of the bound portion of material to be tied; and
[0032] a biasing member is provided in said reception portion for biasing said tie assembly to the reception space.
[0033] (17) The tie attachment device according to one of any (13) to (16) above, wherein said operating means has an operation lever provided slidably, and a connecting member provided slidably to said operation lever at the opposite side of supporting point of the operation lever,
[0034] wherein an extruding rod has a extruding member fixed to its front end, and is inserted into a connecting hole formed on said connecting member, and moving the connecting member and the extruding rod as a unit by obliquely contacting the connection hole of the connecting member to the extruding rod when the operation lever is pulled.
[0035] According to the invention described herein, when opening both ends within the elasticity distortion range the clearance between both ends are larger than the minimum width of a bound portion of the material to be tied, thereby material to be tied can be guided to inside by opening both ends, and bundling of the material to be tied can be tightened and fixed by the restoration strength of the wire rod because the maximum inner diameter in a restored state is smaller than the minimum width of the bound portion of the material to be tied.
[0036] According to the invention described herein, the material(s) can be bound more securely by using the invention when binding a pair of materials to be tied. According to the invention described herein, providing an intersectional portion of crossed materials to be tied as the bound portion, the crossed materials to be tied can be bound in an intersectional state. According to the invention described herein, binding a plurality of material to be tied which are arranged in parallel and attaching these to the outside of the bound portion, thereby these can be tightened from outside and it is easy to bind them.
[0037] According to the invention described herein, both ends of an arc wire rod have a curved portion curved opposite to the curving direction of the arc thereby it is easy to insert the inserting body between both ends of the arc wire rod and the work of opening both ends against the elastic force can easily be done. According to the invention described herein, the wire rod has a rupture portion to be ruptured when a deformation value exceeds the elasticity limit, thereby the arc wire rod can easily be ruptured by expanding and exceeding the elasticity limit and the work of removing a tie from the bound portion can easily be done.
[0038] According to the invention described herein, when opening both ends of the arc wire rod, the rupture portion is located in a center portion, the position where stress is concentrated the most, thereby the tie can easily be ruptured and removed. According to the invention described herein, the rupture portion is a portion smaller in area of cross section compared to other portions, thereby the concentration of stress is further accelerated and the rupture operation can easily be done. According to the invention described herein, the rupture portion is a groove or a cut formed in a direction perpendicular to the axial direction of the wire rod, thereby the process of forming the rapture portion can be made easily.
[0039] According to the invention described herein, the wire rod is in a shape that both ends intersect in a restoration state, thereby a large distortion amount can be taken when binding and the tightening force can further be increased. According to the invention described herein, because the wire rod has a loop when both end of the tie are expanded, the length of wire rod will be longer, distortion on the wire rod is equalized and reduced, and a distortion amount (the width of both ends expanded) can further be increased. Also, the contacting portion of the tie and materials to be tied can be increased, thereby further securely binding.
[0040] According to the invention described herein, a plurality of ties can be carried as a unit by a tie assembly connecting inserting member inserted slidably between both ends of a tie through a thin walled connecting portion. Consequently, when attaching ties at a work site where a number of bound portions exist, work can be done by removing ties from the end in order, thereby working efficiency can be increased. According to the invention described herein, by operating the operation means to progress extruding member, the tie positioned in the reception space is pushed out forward. The tie is pushed open while progressing, and detached from the guiding member and attached to the materials to be tied when both ends of the tie are in a position exceeding the materials to be tied housed between the guiding member. By using such a device, attachment of the tie to materials to be tied can be made easily and quickly.
[0041] According to the invention described herein, a groove is formed on an external face of the guiding member to guide both end portions of a tie, thus, the tie can be guided to the position exceeding the front end of the guiding member. According to the invention described herein, a storing portion is provided between the guiding member and the extruding member to feed the tie into the reception space, thereby the tie can easily be loaded to the tie attachment device. According to the invention described herein, the tie assembly is housed in a storing portion and the bias member is provided in the storing portion thereby the attachment operation of the tie can be made continuously without an operation of loading one tie at a time. This increases the efficiency of the binding work.
[0042] According to the invention described herein, by sliding the operation lever, the connecting member extrudes the extruding member forward. When the connecting member moves forward, it contacts the connecting hole of the connecting member obliquely against the extruding rod, which further applies a force to move it forward, thereby the edge of the connecting hole is pressed by the extruding rod, which strengthens the connection of the extruding rod and the connecting member, and the extruding rod moves as a unit with the connecting member. Consequently, the extruding rod extrudes the extruding member and the tie is attached. The point for applying the force to slide the operation lever acts as a point of application and the connecting hole acts as a point of action. Further, adjusting the length of the operation lever generates a force to easily extrude the tie manually, and a simple and lightweight attachment device can be configured without driving equipment, such as motors.
BRIEF DESCRIPTION OF THE DRAWINGS
[0043] FIG. 1 is an overall perspective view showing a tie.
[0044] FIG. 2 is an overall plane view of a tie in a restored state.
[0045] FIG. 3 is an enlarged perspective view of an inserting member.
[0046] FIG. 4 is a side view showing a tie assembly.
[0047] FIG. 5 is an overall perspective view of a tie attachment device.
[0048] FIG. 6 is an overall side view of a tie attachment device.
[0049] FIG. 7 is a perspective view showing a state when the tie is attached.
[0050] FIG. 8 is an overall plane view showing a tie in another configuration.
[0051] FIG. 9 is an overall plane view showing a tie in another configuration.
[0052] FIG. 10 is a plane view of a tie showing a state of attachment to a bound portion.
[0053] FIG. 11 is an overall plane view of another configuration example of a tie.
DETAILED DESCRIPTION OF THE INVENTION
[0054] Detail of embodiments according to the present invention is hereinafter explained referring to the drawings. FIG. 1 is an overall perspective view of a tie according to present invention, and FIG. 2 is an overall plane view of a tie in a restored state. The tie 1 is configured by forming a wire rod 10 consisting of elastic material in a generally toric shape, and a metal spring material is used as an elastic material. In this embodiment, a cross section of the wire rod 10 is formed in a circular form and end portions alternately overlapping each other and forming a toric shape when in a non-deformed state (restored state) as shown in FIG. 2 .
[0055] Both end portions 11 a and 11 b of the wire rod 10 having curved portions 110 a and 110 b curved opposite to the curving direction of the wire rod 10 , and an inserting member 2 is inserted between the curved portions 110 a and 110 b in a loaded state as shown in FIG. 1 . The inserting member 2 pushes open both ends of wire rod 10 , forming a clearance between the curved portions 110 a and 110 b while the wire rod 10 is in an elastic deformation state. Therefore, when the inserting member 2 is removed from the tie 1 with inserting member 2 inserted, a force to return to the restored state is acting. Also, a suppressed stress is consistently acting from the curved portions 110 a and 110 b in a direction to sandwich and attempt to crush the inserting member 2 .
[0056] FIG. 3 is an enlarged perspective view of the inserting member 2 , and FIG. 4 is a side view of the tie assembly 100 . The inserting member 2 is a plate form member having a thickness longer than the length of the wire rod 10 of tie 1 , and the side face of both ends contact the curved portions 110 a and 110 b are provided with depressed portions 21 a and 21 b having curvatures according to the curves of curved portions 110 a and 110 b . Also, a groove 23 is formed in a circumferential direction on the side face of inserting member 2 , and both ends of the groove are connected to curved portion grooves 22 a and 22 b from in the depressed portions 21 a and 21 b . The groove 23 and the curved portion grooves 22 a and 22 b are formed in a shape corresponding to the cross section shape of wire rod 10 . Also, the groove 23 is formed on a position closer to one of the upper face 211 a or lower face 211 b (one side) in the thickness direction of the inserting member 2 .
[0057] When attached to the tie 1 , the groove 23 is formed on a side face 24 , the side of the tie 1 is positioned, and the side face 24 is formed in a convex along the curve of the tie 1 . Also, on a plane of the side where the groove 23 is formed, a fit portion 26 in a depressed shape that the rear end of a guiding member (described later) to be engaged, is formed. This fit portion 26 is formed to conform to the rear end portion of the guiding member, and in a shape that the width and the depth gradually decreases so that the opening portion is the deepest. Connecting portions 27 a and 27 b are provided to front end side end portions of the upper 211 a and lower 211 b faces of the inserting member 2 , and by these connecting portions 27 a and 27 b , inserting members 2 layered in the thickness direction are alternately connected. The connecting portions 27 a and 27 b are specially formed as thin-walled, and configured to be able to be ruptured with a small shear stress.
[0058] As shown in FIG. 4 , a plurality of inserting members 2 are serially coupled by the connecting portions 27 a and 27 b , and the ties 1 are attached to each inserting member. In this way, a tie assembly 100 is configured. The inserting portions 2 configured as above consist of, for example, a synthetic resin. FIG. 5 is an overall perspective view of a tie attachment device 6 , and FIG. 6 is an overall side view of the same. The tie attachment device 6 is provided with a guiding member 61 which guides the tie 1 so as to fit outside of the binding portion of the reinforcing bars while opening the tie 1 , a storing portion 62 positioned posterior to the guiding member 61 to store the tie 1 , an extruding member 63 positioned posterior to the storing portion 62 , an extruding rod 64 having the extruding member 63 fixed to its front end, a main body 65 to support the extruding rod 64 so as to move freely in an antero-posterior direction, an operation lever 66 slidably supported by the main body 65 , and a connecting member 67 having a connecting hole in which the operation lever 66 is inserted.
[0059] The guiding member 61 has guiding portions 611 a and 611 b that respectively press curved portions 110 a and 110 b on both ends of the tie 1 from outside, the guiding portions 611 a and 611 b are connected to the rear end (back end) and configured to gradually increase the clearance of both towards the front end, and a storing portion 610 is formed between guiding portion 611 a and 611 b . The guiding member 61 is fixed on a base material 60 protruding anterior to the main body 65 , and onto the base material 60 , a reception space 620 to be described later is provided between the main body 65 and the guiding member 61 . The intersectional portion (bound portion) of a vertical reinforcement Sr 1 and a horizontal reinforcement Sr 2 is housed in the storing portion 610 , and between the top ends of guiding portions 611 a and 611 b is an opening 612 for bringing the reinforcing bars into the storing portion 610 .
[0060] Outer side faces of each guiding portion 611 a and 611 b are guiding faces that contact the curved portions 110 a and 110 b of tie 1 and guide in a way that twist around a reinforcing bar inside the storing portion 610 while pressing open the curved portions 110 a and 110 b , and grooves 613 a (not shown) and 613 b formed to this guiding face along the axial direction of the guiding portions 611 a and 611 b . One side (lower side in FIG. 5 ) of grooves 613 a (not shown) and 613 b is formed higher and the other side (upper side in FIG. 5 ) is formed lower, and configured to position the wire rod 10 main body of tie 1 to the side that is formed lower.
[0061] The grooves 613 a (not shown) and 613 b are provided to the guiding portions 611 a and 611 b continuously from the rear end to the top end. In the back end portion of the guiding member 61 , the guiding portions 611 a and 611 b are integrated, with the height and width gradually decreasing towards the posterior, and the rear end is formed in an acute angle. To this rear end, the inserting member 2 of loaded tie 1 is layered, and the fit portion 26 of inserting member 2 is fitted to the rear end portion 615 of guiding member 61 . A reception space 620 is provided posterior to the guiding member 61 to house the tie 1 , further, the extruding member 63 is provided posterior to the reception space 620 . The extruding member 63 is formed in an arc along the curve of wire rod 10 , and a groove 631 (not shown) is formed to place the tie 1 inside. By this groove 631 (not shown), the tie 1 is prevented from separating from the extruding member 63 .
[0062] Also, the curvature of extruding member 63 is formed to conform to the curvature of wire rod 10 when the tie 1 is pressed open to the maximum by the guiding member 61 as described later, instead of the curvature of tie 1 when housed inside the reception space 620 . The top end of extruding rod 64 is connected posterior to the extruding member 63 , and the extruding rod 64 supports the extruding member 62 so as to move freely in an antero-posterior direction The extruding member 63 contacts the main body 65 , and being slidably supported in an axial direction by this main body 65 . The main body 65 is provided with a front support portion 651 and a back support portion 652 that slidably support the extruding rod 64 , and a grip portion 656 projected in a direction almost perpendicular to the extruding rod 64 .
[0063] The inserting hole to insert the extruding rod 64 formed on the front supporting portion 651 is formed sufficiently larger than the diameter of extruding rod 64 , and a play occurs between the inserting hole and the extruding rod 64 . A plate-shaped lock member 654 is provided posterior to the back supporting portion 652 . One end of the lock member 654 is slidably supported by the main body 65 , and inserting hole 654 a is formed in center portion to insert the extruding rod 64 . A compression spring 655 is inserted between the other end of lock member 654 and the main body 65 .
[0064] The lock member 654 is maintained by the compression spring 655 in a position against the extruding rod 64 . At this time, the edge of inserting hole 654 b touches the side face of extruding rod 64 and maintains the extruding rod 64 to be incapable of sliding backwards, thereby locking the backward movement of extruding rod 64 . This lock is released by pressing in the lock member 65 against the compression spring 655 and positioning perpendicular to the extruding rod 64 , thereby the extruding rod 64 is in a state capable of moving backwards.
[0065] The operation lever 66 is slidably supported pivotally at a supporting point 663 to the front side of grip portion 656 , and the handle portion 661 is configured to approach and depart to/from the grip portion 656 . The connecting member 664 is slidably supported pivotally to the end portion on the opposite side of the grip portion 661 centering on the supporting portion 663 through the supporting point 662 . In the center of connecting member 664 , a connecting hole 665 is formed to insert the extruding rod 64 , and the diameter of connecting hole 665 is formed to be slightly larger than that of extruding rod 64 . Also, the compression spring 653 is inserted between the connecting member 664 and front supporting portion 651 which biases the connecting member 651 in a posterior direction.
[0066] In such configuration, the supporting point 664 is extruded forward when sliding the operation lever 66 to the grip portion 656 . By the movement of supporting point 664 , the connecting member 664 slants to the extruding rod 64 , thereby the edge of connecting hole 665 contacts the side face of extruding rod 64 . This contact increases a friction coefficient of the connecting hole 665 and extruding rod 64 , and the extruding rod 64 and connecting member 664 move forward as a unit against the biasing force of compression spring 653 . When returning the operation lever 66 to the original position, the connecting member 664 is in a position almost perpendicular to the extruding rod by the biasing force of compression spring 653 , thereby contacting the edge of the connecting hole 665 and the extruding rod 64 is released and only the connecting member 664 returns to the original position. Also, on the upper side of reception space 620 , reception portion 62 is provided to house a tie assembly 100 , the housed tie assembly 100 is pushed into the reception space 620 by the spring 621 as a biasing member provided between the inner wall of reception portion 62 and the feeding member 622 .
[0067] In addition, a bursiform collecting portion 67 is provided on the lower side of storing portion 610 rear end, and having an opening on the storing portion 610 side. The collecting portion 67 receives inserting member 2 dropped from the reception portion 610 in its inside and collects them. In the tie assembly 100 , the tie 1 positioned undermost is positioned in the reception space 620 . The fit portion 26 of inserting member fits to the rear end portion 615 of guiding member 61 and the tie 1 in the reception space 620 . When the tie 1 inside the reception space 620 is extruded forward by the extruding member 63 , first, the curved portions 110 a and 110 b detach from the depressed portions 21 a and 21 b of inserting member 2 , and move into the grooves 613 a and 613 b provided on the guiding portions 611 a and 611 b of guiding member 61 .
[0068] When the extruding member 63 is further extruded forward, the tie 1 progresses while the curved portions 110 a and 110 b are pressed open right and left by the guiding portions 611 a and 611 b . Next, the rear end portion of wire rod 10 contacts the inserting member 2 , and the wire rod 10 fits within the groove 23 of inserting member 2 , thereby further extruding inserting member 2 forward. At this time, connecting portions 27 a and 27 b connected adjacent to inserting portion 2 in the tie assembly 100 , and the undermost inserting member 2 is detached from the tie assembly 100 .
[0069] The detached inserting portion 2 moves along with tie 1 , drops downward as it reaches storing portion 610 , and is collected in the collecting portion 67 . Meanwhile, the bound portion which is an intersection of the horizontal reinforcement Sr 2 and the vertical reinforcement Sr 1 , is positioned within the storing portion 610 , and the curved portions 110 a and 110 b of tie 1 guided by the guiding member 61 so as to go around outside the bound portion. As the curved portions 110 a and 100 b of tie 1 reach the top end of guiding member 61 , the tie 1 detaches from the guiding member 61 , decreases its diameter by the restoration force of the wire rod 10 , and attaches to the bound portion which is an intersection of the vertical reinforcement Sr 1 and horizontal reinforcement Sr 2 , as shown in FIG. 7 .
[0070] The tie 1 is configured such that the inner diameter in the restored state as shown in FIG. 2 is smaller than the sum of diameters of binding horizontal reinforcement Sr 2 and vertical reinforcement Sr 1 , and the distance between the curved portions 110 a and 110 b is larger than the sum of the diameters of binding horizontal reinforcement Sr 2 and vertical reinforcement Sr 1 when expanded within the elasticity limit of wire rod 10 . In addition, in order for the tie 1 to be able to be easily removed after the attachment, the tie 1 can be configured such that a groove or a cut is formed on the center portion, thereby it can easily be plastically deformed or ruptured at the groove or cut when deformed to exceed an elasticity limit. In this case, the rupture portion configured by forming a groove or a cut may be a site where the form of the wire rod 10 in the axial direction is discontinuous, or it may be a site where an area of cross section is smaller compared to other portions. Alternatively, it may be a site with a different composition. The site with different a composition can be provided by applying treatment different from other parts, such as quenching, annealing, or shot-peening.
[0071] FIG. 8 is a plane view showing a tie 1 A having loop 12 a formed on a center position of the wire rod 10 A. The loop 12 A is an annular section formed outside by curving the wire rod 10 A opposite to the main body portion formed in an arc. By providing the loop 12 A, distortion on the wire rod 10 A which occurs when opening both end portions 11 a and 11 b , can be even equalized and decreased as a whole thereby a larger opening W of both end portions 11 Aa and 11 Ab can be realized. This enables use of a smaller wire rod.
[0072] The tie 1 B shown in FIG. 9 has a plurality of loops 14 B 1 - 14 B 5 at even intervals, and contacting portions 15 B 1 - 15 B 6 are provided in-between these loops 14 B 1 - 14 B 5 . For this tie 1 B, the clearance of both ends 11 Ba and 11 Bb can also be widened when deformed, and each contacting portion 15 B 1 - 15 B 6 can be in pressure contact against intersectional reinforcing bars as shown in FIG. 10 , thereby increasing contacting portions against the reinforcing bars. This increases the binding strength of the bound portion.
[0073] FIG. 11 is an overall plane view of another configuration example of a tie. A tie 1 C has a loop 12 C on the center of a wire rod, and wire rods 13 Ca and 13 Cb on both sides of the loop are formed in line symmetrical across a center line L which runs through the loop 12 C. That is, the wire rods 13 Ca and 13 Cb are formed by extending a pair of wire rods which is parallel in a same direction with reference to the loop 12 C as a base end, towards a direction away from the center line L, curving it to the direction of center line L at the curved portions 141 Ca and 141 Cb, and curving outward (direction away from the center line L) at the curved portions 143 Ca and 143 Cb on the top end side of curved portion 141 Ca and 141 Cb, further curving towards the center line L at the curved portion 142 Ca and 142 Cb on the top end side. The wire rods 13 Ca and 13 Cb are configured with an elastic material as the tie in the embodiments described above. Top end portions 11 Ca and 11 Cb of each wire rod 13 Ca and 13 Cb are curved outward and configured to slide and contact easily to the grooves 613 a and 613 b of guiding member 61 . As described above, in the tie 1 C, the wire rods 13 Ca and 13 Cb on left and right are in line asymmetry wave forms, thus reception retention portions 151 and 152 are formed between the wire rods 13 Ca and 13 Cb to house a horizontal reinforcement and a vertical reinforcement respectively. Each of the reception retention portions 151 and 152 according to this embodiment are in virtually rectangle forms and in the forms that retain horizontal reinforcement and vertical enforcement respectively, thereby increasing contact portions of the horizontal reinforcement and the vertical reinforcement with the wire rods 13 Ca and 13 Cb, which improves the retaining force. Also, the form of each reception retention portion 151 and 152 is not limited to a rectangle, and may be in other polygonal shapes or a circular shape. | The present invention provides a reinforcing bar tie the enables the connection intersecting reinforcing bars. The invention houses a tie made of an elastic member in a reception space, and extrudes it with an extruding member. At this time, the curved portions provided on both ends of the tie advance while guiding portions and of a guide member push them open, and are guided to an intersecting position of two reinforcing bars. Further, by extruding with the extruding member the tie detaches from the guiding member and winds around the intersection of the two reinforcing bars with a force sufficient to couple the two reinforcing bars together. | 4 |
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